Yamaha road star 1700 service manual download

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Fully pull the brake lever or fully press down the brake pedal and hold it in position. 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. Tighten the bleed screw and then release the brake lever or brake pedal. Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

Tighten the bleed screw to specification. After bleeding the hydraulic brake system, check the brake operation. Loosen both locknuts 1. Turn the shift rod 2 in direction b or c to obtain the correct shift pedal position. Direction b. Tighten both locknuts. Make sure the installed shift rod length is within specification. A drive belt that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.

Therefore, keep the drive belt slack within the specified limits. NOTE: Measure the drive belt slack when the engine is cold, and when the drive belt is dry. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated. Use them as a standard for measuring the drive belt slack.

Turn both adjusting bolts 2 in direction a or b until the specified drive belt slack is obtained. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5. NOTE: Set the torque wrench at a right angle to the spanner wrench.

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. Install the rubber washer 3. Install the upper ring nut 2. 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.

Install the lock washer 1. NOTE: Make sure the lock washer tabs sit correctly in the ring nut slots. Hold the motorcycle upright and apply the front brake. Uneven adjustment can result in poor handling and loss of stability.

Never go beyond the maximum or minimum adjustment positions. Adjusting positions a Minimum: Never turn the spring preload adjusting nut beyond the maximum or minimum setting. It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately.

Minimum tire tread depth 1. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.

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.

New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately km should be traveled at normal speed before any high-speed riding is done. Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. Damaged outer cable may cause the cable to corrode and interfere with its movement.

Replace damaged outer cable and inner cables as soon as possible. Recommended lubricant 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 lubricating device. Recommended lubricant Lithium-soap-based grease. Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Get immediate medical attention.

Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. The MF battery should be charged as explained in the charging method illustrations.

If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

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 measuring the voltage at the battery terminals. Connect a pocket tester to the battery terminals. Check the charge of the battery, as shown in the charts and the following example. Example c. If charging has to be done with the battery mounted on the motorcycle, disconnect the negative battery lead from the battery terminal.

A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. Hot batteries can explode! Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be overcharged. If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery. Set the timer to the charging time determined by the opencircuit voltage.

If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Under This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended. Charger Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect the pocket tester to the fuse and check the continuity. Pocket tester YU b. Install a new fuse of the correct amperage rating. Set on the switches to verify if the electrical circuit is operational. If the fuse immediately blows again, check the electrical circuit.

Never use a fuse with an amperage rating 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.

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 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. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi.

Reflector bracket left and right Brake hose holder Reflector left and right Brake caliper left and right Front fork guard left and right Wheel axle pinch bolt Front wheel axle. Do not attempt to straighten a bent wheel axle. Radial wheel runout limit 1. Clean the outside of the front wheel hub. 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. Remove the wheel bearings 3 with a general bearing puller.

Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 4 or balls 5. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal.

Brake disc deflection limit maximum Front: 0. Place the motorcycle on a suitable stand so that the wheel is elevated. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Measure the deflection 1. Brake disc thickness limit minimum Front: 4. Remove the brake disc. Rotate the brake disc by one bolt hole.

Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. If the brake disc deflection cannot be brought within specification, replace the brake disc. Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

NOTE: When installing the front fork guards, make sure that there is not dirt between the guard and the front fork. Spin the front wheel. Release the front wheel. Repeat steps d through f several times until all the marks come to rest at the same spot. NOTE: Start with the lightest weight.

If the heavy spot does not stay in that position, install a heavier weight. Repeat steps b and c until the front wheel is balanced. Turn the front wheel and make sure it stays at each position shown. If the front wheel does not remain stationary at all of the positions, rebalance it. Remarks Remove the parts in the order listed. For installation, reverse the removal procedure. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

Remove the self-locking nuts and the rear wheel pulley. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the pulley.

Install the new rear wheel pulley. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. Install the rear wheel pulley with its wider spokes situated on top of the rear wheel spokes. NOTE: Temporarily tighten the wheel axle nut.

The following procedure applies to both of the front brake calipers. Disc brake components rarely require disassembly. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. Brake pad wear limit 0.

Put the other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Tighten the bleed screw. 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 rotation. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger. Install a new brake pad shim 3 onto each new brake pad 4.

Install new brake pads. For assembly, reverse the disassembly procedure. Brake master cylinder bracket Rear brake light switch Horn 1 connector Right footrest assembly right.

NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Recommended brake fluid DOT 4. Proper brake hose routing is essential to insure safe motorcycle operation. Correct if necessary.

When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a onto brake master cylinder bracket, as shown. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. Secure the right side brake caliper pistons with a piece of wood a.

Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper. Remove the brake caliper piston seals. Repeat the previous steps to force out the right side pistons from the brake caliper. Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper.

Be careful not to get injured when the pistons are expelled from the brake caliper. When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper. Remove: brake caliper Install: brake pad springs brake pad brake caliper brake caliper retaining bolts T.

Front fender Upper bracket pinch bolt Cap bolt Turn signal light bracket pinch bolt Lower bracket pinch bolt Front fork leg. The following procedure applies to both of the front fork legs. Loosen: upper bracket pinch bolts 1 cap bolt 2 turn signal light bracket pinch bolt 3 lower bracket pinch bolts 4. Before loosening the upper and lower bracket pinch bolts and turn signal light bracket pinch bolt, support the front fork leg.

Press down on the spacer with the fork spring compressor 4. Install the rod holder 5 between the nut 3 and the spacer 2. Spring free length mm 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: While holding the damper rod assembly with the damper rod holder 2, tighten the damper rod assembly bolt. Make sure the numbered side of the oil seal faces down. Fully compress the front fork leg. Other oils may have an adverse effect on front fork performance. 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. NOTE: Be careful not to stroke the outer tube over mm 8. If the outer tube is stroke more than mm 8. 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. Front fork leg oil level from the top of the outer tube and damper rod, with the outer tube fully compressed, and without the spring mm 3.

Remove the rod puller. Install the nut 1. Install the rod puller onto the damper rod. Rod puller YM d. Install the fork spring, spring seat, and spacer. Press down on the spacer with the fork spring compressor 6. Pull up the rod puller and install the rod holder between the nut 1 and the spacer 4.

Install the nut 1 and position it as specified b. Distance b Hold the nut and tighten the cap bolt until it comes into contact with the nut. Hold the cap bolt and tighten the nut to specification. The fork spring is compressed. Always use a new cap bolt O-ring.

NOTE: Make sure the outer fork tube is flush with the top of the upper bracket. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: Align the match marks a on the handlebar with the upper surface of the lower handlebar holder. Apply a thin coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag.

Do not touch the handlebar grip until the rubber adhesive has fully dried. Front fork legs Steering stem nut Upper bracket Cable guide Headlight bracket Brake hose bracket Brake hose joint Turn signal light bracket assembly. Lower bracket Lower bearing Lower bearing cover Upper bearing cover Upper bearing Bearing outer race. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.

Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Temporarily tighten the lower bracket pinch bolts. Adjusting bolt 2 Locknut 2 Lower drive belt cover plate 1 Spacer 1 Lower drive belt cover 1 Horn 2 coupler 1 Disconnect.

Horn 2 1. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.

High heat can cause an explosion due to excessive gas pressure. Rear shock absorber damage will result in poor damping performance. If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play at the end of the swingarm 1 mm 0. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.

Wipe the drive belt with a clean cloth. Put the drive belt in a mixture of mild detergent and water. Then, remove any dirt from the drive belt. Remove the drive belt from the mixture and rinse it off with clean water. Then, let the drive belt thoroughly dry. Install the drive belt facing the same way it was removed. Do not twist the drive belt when installing it. NOTE: When tightening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move.

Remarks Drain. NOTE: Place a suitable stand under the frame and engine. Upper mounting bolt Upper mounting bracket bolt Upper mounting Self-locking nut Front mounting bolt Front engine bracket self-locking nut Front engine bracket Front engine bracket bolt Self-locking nut Upper rear mounting bolt.

Install: self-locking nut 5, 6 rear engine bracket left 7 rear engine bracket right 8 upper rear mounting bolt 9 self-locking nut 0 front engine bracket A front mounting bolt B self-locking nut C upper engine bracket D upper mounting bolts E. Turn the crankshaft clockwise. Rocker arm inside diameter Rocker arm shaft outside diameter Above 0.

Rocker arm to rocker arm shaft clearance 0. Valve lifter outside diameter Valve lifter case inside diameter Valve lifter-to-valve lifter case clearance 0. Fill a container with kerosene and place the valve lifter into the container as shown.

Pump the plunger side of the valve lifter with a press a number of times to let in kerosene. Start the engine and warm it up. Stop the engine. Remove the camshaft sprocket cover. Rotate the camshaft until the punch mark 1 on the camshaft driven gear aligns with the punch mark on the camshaft drive gear as shown.

This is the condition in which piston 1 is at top dead center TDC. With piston 1 at TDC, count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown. When these marks align between the centers of the camshaft drive and driven gears, the corresponding valve lifter is at its highest point. Rotate the crankshaft unit the mark on the camshaft driven gear for the valve lifter to be bled aligns with the camshaft drive gear as shown.

Example: For bleeding the cylinder 2 intake valve lifter, align mark 2 as shown. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lifter to bleed. The illustration is viewed from the right side of the motorcycle. Therefore, be sure to install them in the proper position. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern.

Rocker arm base bolt 1 10 Nm 1. Remove: front cylinder camshaft end cover camshaft drive gear 1 camshaft driven gear 2 straight keys. NOTE: Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase. After all of the bolts are fully loosened, remove them. Camshaft lobe dimension limit Intake camshaft a Camshaft journal diameter crankcase side Camshaft journal diameter camshaft cover side Crankcase hole inside diameter Camshaft cover hole inside diameter NOTE: Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter.

Camshaft to crankcase clearance 0. NOTE: Calculate the clearance by subtracting the camshaft journal diameter camshaft cover side from the camshaft cover hole inside diameter. Camshaft to camshaft cover clearance 0. The teeth of both camshaft driven gears must be aligned for installation. Maximum cylinder head warpage 0. Place a straightedge and a thickness gauge across the cylinder head. Measure the warpage.

If the limit is exceeded, resurface the cylinder head as follows. NOTE: To ensure an even surface, rotate the cylinder head several times. The following procedure applies to both cylinders. NOTE: Before removing the internal parts of the cylinder head e.

Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal. Remove: upper spring seat 1 outer valve spring 2 inner valve spring 3 valve 4 valve stem seal 5 lower spring seat 6. NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. Valve-stem-to-valve-guide clearance Intake 0. Remove the valve guide with the valve guide remover 1.

Install the new valve guide with the valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.

NOTE: After replacing the valve guide, reface the valve seat. Valve margin thickness 0. Valve seat width Intake 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression.

Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. Do not let the lapping compound enter the gap between the valve stem and the valve guide. Apply molybdenum disulfide oil onto the valve stem.

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.

Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. Valve spring free length Intake valve spring Compressed valve spring force installed Intake and exhaust inner valve spring 6.

Spring tilt limit Intake and exhaust inner valve spring 2. Install: lower spring seat 1 valve stem seal 2 valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 into the cylinder head. Valve spring compressor set YM 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Do not use a hammer to drive the piston pin out. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 4.

NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Then, find the average of the measurements. If out of specification, replace the cylinder, and the piston and piston rings as a set. If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

Piston ring side clearance Top ring 0. Piston ring end gap Top ring 0. Piston pin outside diameter Piston pin bore diameter in the piston Install: dowel pins 1 cylinder gasket 2 New Lubricate: piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil. NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. Straighten the lock washer tab. NOTE: There is a built-in damper between the clutch boss and the clutch plate.

It is not necessary to remove the wire circlip 4 and disassemble the built-in damper unless there is serious clutch chattering. NOTE: Measure the friction plate at four places. Clutch plate warpage limit 0. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. NOTE: While holding the generator rotor 6 with the primary sheave holder 7, tighten the crankshaft position sensor rotor bolt.

NOTE: While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss nut. Plastic locking tie Plastic band Rear brake light switch coupler Horn 1 connectors Rider footrest assembly right Stator coil assembly coupler Oil delivery pipe. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch. NOTE: While holding the generator rotor 2 with the primary sheave holder 3, tighten the generator rotor bolt.

Inner rotor-to-outer rotor tip clearance 0. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. Thoroughly wash the crankcase halves in a mild solvent.

Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Install: engine oil pump driven gear 1 engine oil pump driven gear stopper 2 oil delivery pipe 3 bolts 4 10 Nm 1.

Install: oil pump housing 1 oil seals 2 oil pump outer rotor 2 3 oil pump inner rotor 2 4 pin 5 oil pump shaft 6 pins 7 oil pump housing cover 2 8. NOTE: When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor. Crankshaft runout Less than 0. Crankshaft-pin-to-big-end-bearing clearance 0. Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions.

Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. 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 connecting rod and connecting rod cap. Assemble the connecting rod halves.

NOTE: The tightening procedure of the connecting rod bolts is angle controlled, therefore tighten the bolts using the following procedure. Tighten the connecting rod bolts to the specified torque. Replace the bolt with a new one and perform the procedure again. Remove the connecting rod and big end bearings.

If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.

Crankshaft journal diameter Crankshaft journal bearing inside diameter NOTE: Calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside diameter.

Crankshaft journal-to-crankshaft journal bearing clearance 0. Lubricate: crankshaft pins big end bearings connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil.

To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Main axle runout limit 0. Drive axle runout limit 0. NOTE: Oil each gear, shaft, and bearing thoroughly. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

Once a malfunction has been detected, it becomes stored in the ECU memory in the form of a fault code. Once a self-diagnostic fault code has been displayed, it remains stored in the ECU memory until a deletion operation is performed.

Engine trouble warning light indication and FI system operating conditions normal mode Warning light indication. Battery voltage below the specified value defective Fuel injection system relay, engine stop switch turned OFF, or drained battery b.

One of the fault codes listed below has been detected self-diagnostic code 12, 19, 30, 41, or 50 is output : faulty crankshaft position sensor signal open circuit in sidestand input line a fall has been detected open or short circuit in lean angle cutoff switch ECU memory check error. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb.

Therefore, take an appropriate corrective action by referring to the troubleshooting section. Determining the area of the malfunction through the self-diagnostic fault code number The possible location of the system in which a problem may be occurring can be determined by observing the self-diagnostic fault code number that appears on the tachometer and cross-referencing it on the fault code number table.

When used in conjunction with the troubleshooting details, and by checking the possible items one by one, you will be able to identify the cause of the problem in order to carry out an accurate repair work. Warning of the occurrence of a malfunction appears on the tachometer. Determine the area of the problem by referring to the self-diagnostic fault code number. Turn off the main switch. Repair the problem area by referring to the troubleshooting details.

Faulty intake air pressure sensor pipe system 2; a hose is detached, causing the constant application of atmospheric pressure to the sensor; or, the hose is clogged. Faulty intake air pressure sensor pipe system 1; a hose is detached, causing the constant application of atmospheric pressure to the sensor; or, the hose is clogged. Atmospheric pressure sensor or intake air pressure sensor Malfunction of the atmospheric pressure sensor in the intermediate electrical potential.

Malfunction of the intake air pressure sensor in the intermediate electrical potential. Atmospheric pressure sensor open or short circuit detected.

Intake air pressure sensor 2 open or short circuit detected. Oil temperature sensor - open or short circuit detected. Engine temperature sensor open or short circuit detected. Decompression thermostat open or short circuit detected. The motorcycle has overturned. Linear control valve - faulty valve or motor is detected.

Decompression solenoid - open circuit is detected. Lean angle cut-off switch - open or short circuit detected. No normal signals are received from the speed sensor; or, an open or short circuit is detected in the neutral switch.

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter. However, the self-diagnostic fault code of the previous malfunction remains in the ECU memory as part of the malfunction history. To erase the self-diagnostic fault code from the malfunction history, the operation for diagnostic code 62 must be performed in the diagnosis mode. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for every sensor, in order to provide the engine with substitute characteristics operation instructions that enable the engine to continue to operate or to stop its operation, depending on circumstances.

The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given in the table below. Table of substitute characteristic operation control by self-diagnostic fault code Code No. The technician determines whether or not the operation is normal by verifying the values displayed on the tachometer or the operating conditions of the actuators.

These modes can be used to detect and check the problems that are otherwise difficult to detect in the diagnosis mode. Disconnect the wiring harness coupler from the fuel pump. Check the results by referring to the sensor operation data verification table or the actuator operation verification table. Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective cylinder identification sensor.

Malfunction in ECU. Improperly installed sensor. Defective crankshaft position sensor. Malfunction in pickup rotor. Defective intake air pressure sensor. Faulty intake air pressure sensor pipe system 1; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged. Defective throttle position sensor. Improperly installed throttle position sensor. A stuck throttle position sensor is detected. Or, Faulty intake air pressure sensor pipe system; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged.

Defective sensor stuck throttle position sensor. Intake air pressure sensor hose is detached, clogged, kinked, or pinched. Open circuit in the input line from the sidestand switch to the ECU is detected when the start switch is pressed. When the main switch is turned to ON, the atmospheric sensor voltage and intake air pressure sensor voltage differ greatly. Defective intake temperature sensor. Defective atmospheric pressure sensor.

Faulty intake air pressure sensor pipe system 2; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged.

Defective oil temperature sensor. Defective engine temperature sensor. Defective decompression solenoid thermistor. Defective linear control valve. Improperly installed linear control valve. Defective decompression solenoid. Defective lean angle cut-off switch. Defective speed sensor. Malfunction in vehicle speed sensor detected unit.

Defective neutral switch. Malfunction in the engine side of the neutral switch. The program and data are not properly written on or read from the internal memory. Diag code. Displays the throttle angle. Displays the atmospheric pressure.

Displays the pressure difference 1 atmospheric pressure intake air pressure 1. Engine stop switch is on. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates ignition coils 1 for five times every second and illuminates the engine trouble warning light.

Take the same actions as No. Same as above. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the injector five times every second and illuminates the engine trouble warning light. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the fuel injection system relay five times every second and illuminates the engine trouble warning light the light is OFF when the relay is ON, and the light is ON when the relay is OFF.

Check the relay operating After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the head- sound. Same as above light relay five times every 5 seconds and illuminates the engine trouble warning light. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the linear control valve four times every 5 seconds and illuminates the engine trouble warning light fully closed 2 seconds, fully open 2 seconds.

After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the decompression solenoid five times every 5 seconds and illuminates the engine trouble warning light ON 2 seconds, OFF 3 seconds. Checking the self-diagnostic fault code Check the self-diagnostic fault code displayed on the tachometer. Checking the tachometer display Turn the main switch to OFF, then to ON again to check if a self-diagnostic fault code is displayed.

Erasing the malfunction history Even if the main switch is turned to OFF, the malfunction history is recorded. Repair or replace if there is an open or short circuit. Connected state of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect it securely. Used diagnostic code No. Inspection operation item and probable cause Operation item and countermeasure.

Repair or replace if there is an open or short circuit between the main wiring harnesses. Crankshaft position sensor coupler Main wiring harness ECU coupler. Replace if defective. Common to 1, 2, and 3: Connected state of connector Inspect the coupler for any pins that may have pulled out. Intake air pressure sensor coupler Main wiring harness ECU coupler.

Intake air pressure sensor hose detached, clogged, kinked, or pinched. Intake air pressure sensor malfunction at intermediate electrical potential.

Atmospheric pressure sensor malfunction at intermediate electrical potential. Repair or replace the sensor hose. Inspect and repair the connection. Replace it if there is a malfunction. Open circuit item: Output voltage Ground wire open circuit: 5V Output wire open circuit: 0V Power supply wire open circuit: 0 V Check for open circuit and replace the throttle position sensor.

Check the installed area for looseness or pinching. Check that it is installed in the specified position. Throttle position sensor coupler Main wiring harness ECU coupler. Common to 1 and 2: Connected state of connector Inspect the coupler for any pins that may have pulled out.

Open circuit is detected in the input line from the sidestand switch to the ECU. Open or short circuit in wiring harness or Repair or replace if there is an open or short If the transmission sub lead. Connected state of connector If there is a malfunction, repair it and connect it the sidestand. If the transmission Inspect the coupler for any pins that may securely. Main wiring harness ECU coupler reinstated by Check the locking condition of the coupler.

ECU coupler illustration Indicate No. Defective sidestand switch Replace if defective. Code No. Installed state of sensor Check the installed area for looseness or Reinstated by turnpinching.

Open or short circuit in wiring harness or Repair or replace if there is an open or short ON. Connected state of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that may securely.

Intake temperature sensor coupler Check the locking condition of the coupler. Main wiring harness ECU coupler 4. Installed state of atmospheric pressure sen- Check the installed area for looseness or sor pinching.

Atmospheric pressure sensor coupler Main wiring harness ECU coupler. Oil temperature sensor coupler Check the locking condition of the coupler. Main wiring harness Black - Black Brown - Brown 3. Engine temperature sensor coupler Check the locking condition of the coupler. Electricity is not circulated to the decompression solenoid open or short circuit in thermistor is detected Used diagnostic code No.

Installed state of decompression solenoid Check the installed area for looseness or Reinstated by turnpinching. Decompression solenoid coupler Check the locking condition of the coupler. Malfunction in decompression solenoid Replace if defective. Reinstated by turning the main switch Check the installed area for looseness or ON however, the pinching. Main wiring harness ECU coupler. Defective linear control valve Check the operating sound or that the warning light is on 3 times with engine stop switch ON.

Open or short circuit in wiring harness or sub lead. Reinstatement method Perform diagnostic code 54 to check the operation of the linear control valve. Main wiring harness linear control valve couCheck the locking condition of the coupler. Installed state of linear control valve Check the installed area for looseness or pinching. Open or short circuit in wiring harness or Repair or replace if there is an open or short Reinstated by turnsub lead.

Main wiring harness oil temperature sensor Check the locking condition of the coupler. I couldn't find someone in a german forum, who ones the manual. I only got the manual for XV Someone who can help? Tags: None. Update Your Browser Facebook. Comment Post Cancel. Too bad for you I guess. No it is in a file at the top and you can download it to your cell phone also.

Not much difference 04 to 05 , stators upgraded. Originally posted by brianmac View Post. Shores commented. It's on the Facebook link that he gave you in the first comment after your question. Yeah download it to your phone then wherever you are you got the manual in your pocket. Website said it can't upload a PDF file. If someone knows how to upload a PDF here, I can put this file for use on this website.

To JoeX, Yamaha didn't re-write the service manual specifically for the until when they added fuel injection. It covers procedures for both and You might find it on Ebay. Latest Posts. Started by bpcallahan , 5 hours ago. Started by Lug Nut , 6 hours ago. Progressive fork springs by Pauli Started by Pauli , 10 hours ago. Any tips on pulling wires through bars? Started by Kmartcivic , 17 hours ago. No start by Cakeman7. Started by Cakeman7 , 2 days ago.

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Replace a whole front end witha ? Started by drifter , 4 days ago. Started by AsphaltAddict , 5 days ago.

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Make sure all connections are tight and free of corrosion. NOTE: Insufficient compression pressure will result in a loss of performance.

If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Start the engine, warm it up for several min- utes, and then turn it off. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

If the oil filter cartridge is also to be replaced, perform the following procedure. Remove the oil filter cartridge 1 with an oil filter wrench 2. Oil filter wrench YU b. Brake pedal position from the top of the rider footrest to the top of the brake pedal 80 mm 3.

Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

Install the diaphragm brake master cylinder reservoir or brake fluid reservoir. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated.

Loosen the brake caliper bracket bolt 1. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5. Uneven adjustment can result in poor handling and loss of stability. The front and rear tires should always be by the same manufacturer and of the same design. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. Time minutes Check the open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

Connect the pocket tester to the fuse and check the continuity. Install a new fuse of the correct amperage rating. Set on the switches to verify if the electrical circuit is operational. Oil seal left and right Wheel bearing left and right Spacer For assembly, reverse the disassembly procedure. Radial wheel runout limit 1. Remove the brake disc. Rotate the brake disc by one bolt hole. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. NOTE: Start with the lightest weight.

Spacer Bearing Rear wheel For assembly, reverse the disassembly procedure. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

Brake caliper retaining bolt Brake caliper Brake pad 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 rotation. Brake pad wear limit 0. Rear view mirror right Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake fluid Drain.

Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake caliper piston seal Bleed screw For assembly, reverse the disassembly NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. The following procedure applies to both of the front fork legs.

Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure. Loosen the nut. Remove the cap bolt. Remove the rod holder and fork spring com- pressor. Page Quantity each front fork leg cm Other oils may have an adverse effect on front fork performance.

NOTE: Be careful not to stroke the outer tube over mm 8. If the outer tube is stroke more than mm 8. Remove the rod puller. Install the nut 1. Always use a new cap bolt O-ring.

Rear view mirror left and right Plastic clamp Front brake light switch connector Disconnect. Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. NOTE: Temporarily tighten the lower bracket pinch bolts. Before handling the rear shock absorber, read and make sure you understand the following informa- tion.

The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber. Straighten the lock washer tab. Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Plastic clamp Push rod cover O-ring Seal Rocker arm inside diameter Valve lifter outside diameter Fill a container with kerosene and place the valve lifter into the container as shown.

Pump the plunger side of the valve lifter with a press a number of times to let in kero- sene. Rotate the crankshaft unit the mark on the camshaft driven gear for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder 2 intake valve lifter, align mark 2 as shown. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern.

Rocker arm base bolt 1 10 Nm 1. Camshaft lobe dimension limit Intake camshaft a Crankcase hole inside diameter Valve cotter Upper spring seat Outer valve spring Inner valve spring NOTE: Before removing the internal parts of the cylin- der head e. Valve margin thickness 0. Valve seat width Intake 0. Valve spring free length Intake valve spring Valve spring compressor set YM 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. Piston pin bore diameter in the piston Clutch cover gasket Dowel pin For installation, reverse the removal After all of the bolts are fully loosened, remove them. Clutch plate warpage limit 0. Starter clutch idle gear shaft 2 Starter clutch idle gear shaft 1 Starter clutch idle gear 2 Starter clutch idle gear 1 Generator rotor Woodruff key Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch.

Oil temperature sensor Oil tank left cover Oil tank left cover gasket Bend the lock washer tab along a flat side of the nut. Baffle plate Oil seal Bearing For installation, reverse the removal procedure. Crankcase Separate. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal Assemble the connecting rod halves.

Crankshaft journal diameter NOTE: Calculate the clearance by subtracting the crankshaft journal diameter from the crank- shaft journal bearing inside diameter. Replace the bolt with a new one and per- form the procedure again. NOTE: Oil each gear, shaft, and bearing thoroughly. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb. Disconnect the wiring harness coupler from the fuel pump. The engine trouble warning light comes on. The engine trouble warning light does not come on. Symptom No normal signals are received from the cylinder identification sensor. Used diagnostic code No. Inspection operation item Operation item and countermeasure Reinstatement method 2. Defective cylinder identification sensor.

Replace if defective. Symptom Intake air pressure sensor 1 - open or short circuit detected. Open or short circuit in wiring harness or Repair or replace if there is an open or short Reinstated by turn- sub lead.

Symptom 1 Intake air pressure sensor 1 - pipe system malfunction clogged or detached hose. Symptom Throttle position sensor - open or short circuit detected.

Installed state of throttle position sensor. Check the installed area for looseness or Reinstated by turn- pinching. Symptom 1 Stuck throttle position sensor detected.

Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Open or short circuit in wiring harness or Repair or replace if there is an open or short If the transmission Symptom Open or short circuit detected from the atmospheric pressure sensor. Installed state of atmospheric pressure sen- Check the installed area for looseness or Reinstated by turn- pinching. Symptom 1 Intake air pressure sensor 2 - pipe system malfunction clogged or detached hose.

Symptom Open or short circuit is detected from the oil temperature sensor. Installed state of sensor Check the installed area for looseness or Reinstated by turn- pinching.

Symptom Electricity is not circulated to the decompression solenoid open or short circuit in thermistor is detected Used diagnostic code No. Installed state of decompression solenoid Check the installed area for looseness or Symptom Faulty liner control valve or motor is detected.

Defective linear control valve Replace if defective. Symptom Open or short circuit detected in the lean angle cut-off switch. Open or short circuit in lead wire.

Repair or replace if there is an open or short Reinstated by turn- circuit. Symptom The ECU is unable to monitor the battery voltage. Malfunction in ECU Fuel injection system relay is on.

Reinstated by starting the engine 2. Open or short circuit in the wiring harness. Fuel is not supplied to the cylinder. No signals are received from the ECU within the specified duration.

For installation, reverse the removal procedure. Engine temperature sensor coupler Disconnect. If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

Set the timer to the charging time determined by the opencircuit voltage. If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Under This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended. Charger Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect the pocket tester to the fuse and check the continuity. Pocket tester YU b. Install a new fuse of the correct amperage rating. Set on the switches to verify if the electrical circuit is operational.

If the fuse immediately blows again, check the electrical circuit. Never use a fuse with an amperage rating 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.

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 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.

If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi. Reflector bracket left and right Brake hose holder Reflector left and right Brake caliper left and right Front fork guard left and right Wheel axle pinch bolt Front wheel axle.

Do not attempt to straighten a bent wheel axle. Radial wheel runout limit 1. Clean the outside of the front wheel hub. 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.

Remove the wheel bearings 3 with a general bearing puller. Install the new wheel bearings and oil seals in the reverse order of disassembly.

Do not contact the wheel bearing inner race 4 or balls 5. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal. Brake disc deflection limit maximum Front: 0. Place the motorcycle on a suitable stand so that the wheel is elevated. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary.

Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Measure the deflection 1. Brake disc thickness limit minimum Front: 4. Remove the brake disc. Rotate the brake disc by one bolt hole. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. If the brake disc deflection cannot be brought within specification, replace the brake disc.

Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. NOTE: When installing the front fork guards, make sure that there is not dirt between the guard and the front fork. Spin the front wheel. Release the front wheel. Repeat steps d through f several times until all the marks come to rest at the same spot. NOTE: Start with the lightest weight. If the heavy spot does not stay in that position, install a heavier weight.

Repeat steps b and c until the front wheel is balanced. Turn the front wheel and make sure it stays at each position shown. If the front wheel does not remain stationary at all of the positions, rebalance it.

Remarks Remove the parts in the order listed. For installation, reverse the removal procedure. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Remove the self-locking nuts and the rear wheel pulley. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the pulley. Install the new rear wheel pulley.

NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. Install the rear wheel pulley with its wider spokes situated on top of the rear wheel spokes.

NOTE: Temporarily tighten the wheel axle nut. The following procedure applies to both of the front brake calipers. Disc brake components rarely require disassembly. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. Brake pad wear limit 0. Put the other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

Tighten the bleed screw. 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 rotation. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger.

Install a new brake pad shim 3 onto each new brake pad 4. Install new brake pads. For assembly, reverse the disassembly procedure. Brake master cylinder bracket Rear brake light switch Horn 1 connector Right footrest assembly right. NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

Recommended brake fluid DOT 4. Proper brake hose routing is essential to insure safe motorcycle operation. Correct if necessary. When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a onto brake master cylinder bracket, as shown. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. Secure the right side brake caliper pistons with a piece of wood a.

Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper. Remove the brake caliper piston seals. Repeat the previous steps to force out the right side pistons from the brake caliper.

Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper. Be careful not to get injured when the pistons are expelled from the brake caliper. When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper.

Remove: brake caliper Install: brake pad springs brake pad brake caliper brake caliper retaining bolts T. Front fender Upper bracket pinch bolt Cap bolt Turn signal light bracket pinch bolt Lower bracket pinch bolt Front fork leg. The following procedure applies to both of the front fork legs. Loosen: upper bracket pinch bolts 1 cap bolt 2 turn signal light bracket pinch bolt 3 lower bracket pinch bolts 4.

Before loosening the upper and lower bracket pinch bolts and turn signal light bracket pinch bolt, support the front fork leg. Press down on the spacer with the fork spring compressor 4. Install the rod holder 5 between the nut 3 and the spacer 2. Spring free length mm 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: While holding the damper rod assembly with the damper rod holder 2, tighten the damper rod assembly bolt. Make sure the numbered side of the oil seal faces down. Fully compress the front fork leg. Other oils may have an adverse effect on front fork performance. 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.

NOTE: Be careful not to stroke the outer tube over mm 8. If the outer tube is stroke more than mm 8. 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. Front fork leg oil level from the top of the outer tube and damper rod, with the outer tube fully compressed, and without the spring mm 3. Remove the rod puller. Install the nut 1. Install the rod puller onto the damper rod. Rod puller YM d. Install the fork spring, spring seat, and spacer. Press down on the spacer with the fork spring compressor 6.

Pull up the rod puller and install the rod holder between the nut 1 and the spacer 4. Install the nut 1 and position it as specified b. Distance b Hold the nut and tighten the cap bolt until it comes into contact with the nut. Hold the cap bolt and tighten the nut to specification. The fork spring is compressed. Always use a new cap bolt O-ring. NOTE: Make sure the outer fork tube is flush with the top of the upper bracket. If there is any contact with the fuel tank, adjust the handlebar position.

NOTE: Align the match marks a on the handlebar with the upper surface of the lower handlebar holder. Apply a thin coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag. Do not touch the handlebar grip until the rubber adhesive has fully dried.

Front fork legs Steering stem nut Upper bracket Cable guide Headlight bracket Brake hose bracket Brake hose joint Turn signal light bracket assembly.

Lower bracket Lower bearing Lower bearing cover Upper bearing cover Upper bearing Bearing outer race. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.

Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Temporarily tighten the lower bracket pinch bolts. Adjusting bolt 2 Locknut 2 Lower drive belt cover plate 1 Spacer 1 Lower drive belt cover 1 Horn 2 coupler 1 Disconnect.

Horn 2 1. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. High heat can cause an explosion due to excessive gas pressure. Rear shock absorber damage will result in poor damping performance.

If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play at the end of the swingarm 1 mm 0. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers. Wipe the drive belt with a clean cloth. Put the drive belt in a mixture of mild detergent and water. Then, remove any dirt from the drive belt. Remove the drive belt from the mixture and rinse it off with clean water.

Then, let the drive belt thoroughly dry. Install the drive belt facing the same way it was removed. Do not twist the drive belt when installing it. NOTE: When tightening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move. Remarks Drain. NOTE: Place a suitable stand under the frame and engine. Upper mounting bolt Upper mounting bracket bolt Upper mounting Self-locking nut Front mounting bolt Front engine bracket self-locking nut Front engine bracket Front engine bracket bolt Self-locking nut Upper rear mounting bolt.

Install: self-locking nut 5, 6 rear engine bracket left 7 rear engine bracket right 8 upper rear mounting bolt 9 self-locking nut 0 front engine bracket A front mounting bolt B self-locking nut C upper engine bracket D upper mounting bolts E. Turn the crankshaft clockwise. Rocker arm inside diameter Rocker arm shaft outside diameter Above 0.

Rocker arm to rocker arm shaft clearance 0. Valve lifter outside diameter Valve lifter case inside diameter Valve lifter-to-valve lifter case clearance 0. Fill a container with kerosene and place the valve lifter into the container as shown.

Pump the plunger side of the valve lifter with a press a number of times to let in kerosene. Start the engine and warm it up. Stop the engine. Remove the camshaft sprocket cover. Rotate the camshaft until the punch mark 1 on the camshaft driven gear aligns with the punch mark on the camshaft drive gear as shown.

This is the condition in which piston 1 is at top dead center TDC. With piston 1 at TDC, count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown. When these marks align between the centers of the camshaft drive and driven gears, the corresponding valve lifter is at its highest point. Rotate the crankshaft unit the mark on the camshaft driven gear for the valve lifter to be bled aligns with the camshaft drive gear as shown.

Example: For bleeding the cylinder 2 intake valve lifter, align mark 2 as shown. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lifter to bleed. The illustration is viewed from the right side of the motorcycle. Therefore, be sure to install them in the proper position. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1 10 Nm 1. Remove: front cylinder camshaft end cover camshaft drive gear 1 camshaft driven gear 2 straight keys.

NOTE: Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase. After all of the bolts are fully loosened, remove them. Camshaft lobe dimension limit Intake camshaft a Camshaft journal diameter crankcase side Camshaft journal diameter camshaft cover side Crankcase hole inside diameter Camshaft cover hole inside diameter NOTE: Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter.

Camshaft to crankcase clearance 0. NOTE: Calculate the clearance by subtracting the camshaft journal diameter camshaft cover side from the camshaft cover hole inside diameter.

Camshaft to camshaft cover clearance 0. The teeth of both camshaft driven gears must be aligned for installation. Maximum cylinder head warpage 0. Place a straightedge and a thickness gauge across the cylinder head.

Measure the warpage. If the limit is exceeded, resurface the cylinder head as follows. NOTE: To ensure an even surface, rotate the cylinder head several times. The following procedure applies to both cylinders. NOTE: Before removing the internal parts of the cylinder head e. Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal. Remove: upper spring seat 1 outer valve spring 2 inner valve spring 3 valve 4 valve stem seal 5 lower spring seat 6.

NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. Valve-stem-to-valve-guide clearance Intake 0. Remove the valve guide with the valve guide remover 1. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance. NOTE: After replacing the valve guide, reface the valve seat.

Valve margin thickness 0. Valve seat width Intake 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. Do not let the lapping compound enter the gap between the valve stem and the valve guide.

Apply molybdenum disulfide oil onto the valve stem. 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. Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. Valve spring free length Intake valve spring Compressed valve spring force installed Intake and exhaust inner valve spring 6.

Spring tilt limit Intake and exhaust inner valve spring 2. Install: lower spring seat 1 valve stem seal 2 valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 into the cylinder head. Valve spring compressor set YM 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Do not use a hammer to drive the piston pin out.

If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 4. NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Then, find the average of the measurements. If out of specification, replace the cylinder, and the piston and piston rings as a set. If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula.

NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0. Piston ring end gap Top ring 0. Piston pin outside diameter Piston pin bore diameter in the piston Install: dowel pins 1 cylinder gasket 2 New Lubricate: piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil.

NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. Straighten the lock washer tab. NOTE: There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip 4 and disassemble the built-in damper unless there is serious clutch chattering.

NOTE: Measure the friction plate at four places. Clutch plate warpage limit 0. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. NOTE: While holding the generator rotor 6 with the primary sheave holder 7, tighten the crankshaft position sensor rotor bolt. NOTE: While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss nut.

Plastic locking tie Plastic band Rear brake light switch coupler Horn 1 connectors Rider footrest assembly right Stator coil assembly coupler Oil delivery pipe. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch. NOTE: While holding the generator rotor 2 with the primary sheave holder 3, tighten the generator rotor bolt.

Inner rotor-to-outer rotor tip clearance 0. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Install: engine oil pump driven gear 1 engine oil pump driven gear stopper 2 oil delivery pipe 3 bolts 4 10 Nm 1.

Install: oil pump housing 1 oil seals 2 oil pump outer rotor 2 3 oil pump inner rotor 2 4 pin 5 oil pump shaft 6 pins 7 oil pump housing cover 2 8. NOTE: When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor. Crankshaft runout Less than 0. Crankshaft-pin-to-big-end-bearing clearance 0. Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions.

Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. 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 connecting rod and connecting rod cap.

Assemble the connecting rod halves. NOTE: The tightening procedure of the connecting rod bolts is angle controlled, therefore tighten the bolts using the following procedure. Tighten the connecting rod bolts to the specified torque. Replace the bolt with a new one and perform the procedure again.

Remove the connecting rod and big end bearings. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. Crankshaft journal diameter Crankshaft journal bearing inside diameter NOTE: Calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside diameter.

Crankshaft journal-to-crankshaft journal bearing clearance 0. Lubricate: crankshaft pins big end bearings connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil. To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.

Main axle runout limit 0. Drive axle runout limit 0. NOTE: Oil each gear, shaft, and bearing thoroughly. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

Once a malfunction has been detected, it becomes stored in the ECU memory in the form of a fault code. Once a self-diagnostic fault code has been displayed, it remains stored in the ECU memory until a deletion operation is performed. Engine trouble warning light indication and FI system operating conditions normal mode Warning light indication. Battery voltage below the specified value defective Fuel injection system relay, engine stop switch turned OFF, or drained battery b.

One of the fault codes listed below has been detected self-diagnostic code 12, 19, 30, 41, or 50 is output : faulty crankshaft position sensor signal open circuit in sidestand input line a fall has been detected open or short circuit in lean angle cutoff switch ECU memory check error. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb.

Therefore, take an appropriate corrective action by referring to the troubleshooting section. Determining the area of the malfunction through the self-diagnostic fault code number The possible location of the system in which a problem may be occurring can be determined by observing the self-diagnostic fault code number that appears on the tachometer and cross-referencing it on the fault code number table.

When used in conjunction with the troubleshooting details, and by checking the possible items one by one, you will be able to identify the cause of the problem in order to carry out an accurate repair work. Warning of the occurrence of a malfunction appears on the tachometer. Determine the area of the problem by referring to the self-diagnostic fault code number. Turn off the main switch. Repair the problem area by referring to the troubleshooting details.

Faulty intake air pressure sensor pipe system 2; a hose is detached, causing the constant application of atmospheric pressure to the sensor; or, the hose is clogged.

Faulty intake air pressure sensor pipe system 1; a hose is detached, causing the constant application of atmospheric pressure to the sensor; or, the hose is clogged.

Atmospheric pressure sensor or intake air pressure sensor Malfunction of the atmospheric pressure sensor in the intermediate electrical potential. Malfunction of the intake air pressure sensor in the intermediate electrical potential. Atmospheric pressure sensor open or short circuit detected. Intake air pressure sensor 2 open or short circuit detected. Oil temperature sensor - open or short circuit detected. Engine temperature sensor open or short circuit detected. Decompression thermostat open or short circuit detected.

The motorcycle has overturned. Linear control valve - faulty valve or motor is detected. Decompression solenoid - open circuit is detected. Lean angle cut-off switch - open or short circuit detected. No normal signals are received from the speed sensor; or, an open or short circuit is detected in the neutral switch.

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter. However, the self-diagnostic fault code of the previous malfunction remains in the ECU memory as part of the malfunction history.

To erase the self-diagnostic fault code from the malfunction history, the operation for diagnostic code 62 must be performed in the diagnosis mode. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for every sensor, in order to provide the engine with substitute characteristics operation instructions that enable the engine to continue to operate or to stop its operation, depending on circumstances. The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator.

Details on the fail-safe actions are given in the table below. Table of substitute characteristic operation control by self-diagnostic fault code Code No. The technician determines whether or not the operation is normal by verifying the values displayed on the tachometer or the operating conditions of the actuators.

These modes can be used to detect and check the problems that are otherwise difficult to detect in the diagnosis mode. Disconnect the wiring harness coupler from the fuel pump. Check the results by referring to the sensor operation data verification table or the actuator operation verification table. Open or short circuit in wiring sub lead.

Open or short circuit in wiring harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed sensor. Defective crankshaft position sensor. Malfunction in pickup rotor. Defective intake air pressure sensor. Faulty intake air pressure sensor pipe system 1; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged.

Defective throttle position sensor. Improperly installed throttle position sensor. A stuck throttle position sensor is detected. Or, Faulty intake air pressure sensor pipe system; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged. Defective sensor stuck throttle position sensor.

Intake air pressure sensor hose is detached, clogged, kinked, or pinched. Open circuit in the input line from the sidestand switch to the ECU is detected when the start switch is pressed. When the main switch is turned to ON, the atmospheric sensor voltage and intake air pressure sensor voltage differ greatly.

Defective intake temperature sensor. Defective atmospheric pressure sensor. Faulty intake air pressure sensor pipe system 2; a hose is detached, causing constant application of the atmospheric pressure to the sensor; or, the hose is clogged. Defective oil temperature sensor. Defective engine temperature sensor. Defective decompression solenoid thermistor. Defective linear control valve. Improperly installed linear control valve. Defective decompression solenoid. Defective lean angle cut-off switch.

Defective speed sensor. Malfunction in vehicle speed sensor detected unit. Defective neutral switch. Malfunction in the engine side of the neutral switch. The program and data are not properly written on or read from the internal memory. Diag code. Displays the throttle angle. Displays the atmospheric pressure. Displays the pressure difference 1 atmospheric pressure intake air pressure 1. Engine stop switch is on. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates ignition coils 1 for five times every second and illuminates the engine trouble warning light.

Take the same actions as No. Same as above. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the injector five times every second and illuminates the engine trouble warning light. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the fuel injection system relay five times every second and illuminates the engine trouble warning light the light is OFF when the relay is ON, and the light is ON when the relay is OFF.

Check the relay operating After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the head- sound. Same as above light relay five times every 5 seconds and illuminates the engine trouble warning light. After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the linear control valve four times every 5 seconds and illuminates the engine trouble warning light fully closed 2 seconds, fully open 2 seconds.

After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the decompression solenoid five times every 5 seconds and illuminates the engine trouble warning light ON 2 seconds, OFF 3 seconds.

Checking the self-diagnostic fault code Check the self-diagnostic fault code displayed on the tachometer. Checking the tachometer display Turn the main switch to OFF, then to ON again to check if a self-diagnostic fault code is displayed. Erasing the malfunction history Even if the main switch is turned to OFF, the malfunction history is recorded. Repair or replace if there is an open or short circuit. Connected state of connector Inspect the coupler for any pins that may have pulled out.

Check the locking condition of the coupler. If there is a malfunction, repair it and connect it securely. Used diagnostic code No. Inspection operation item and probable cause Operation item and countermeasure. Repair or replace if there is an open or short circuit between the main wiring harnesses.

Crankshaft position sensor coupler Main wiring harness ECU coupler. Replace if defective. Common to 1, 2, and 3: Connected state of connector Inspect the coupler for any pins that may have pulled out. Intake air pressure sensor coupler Main wiring harness ECU coupler. Intake air pressure sensor hose detached, clogged, kinked, or pinched. Intake air pressure sensor malfunction at intermediate electrical potential.

Atmospheric pressure sensor malfunction at intermediate electrical potential. Repair or replace the sensor hose. Inspect and repair the connection. Replace it if there is a malfunction. Open circuit item: Output voltage Ground wire open circuit: 5V Output wire open circuit: 0V Power supply wire open circuit: 0 V Check for open circuit and replace the throttle position sensor.

Check the installed area for looseness or pinching. Check that it is installed in the specified position. Throttle position sensor coupler Main wiring harness ECU coupler. Common to 1 and 2: Connected state of connector Inspect the coupler for any pins that may have pulled out. Open circuit is detected in the input line from the sidestand switch to the ECU. Open or short circuit in wiring harness or Repair or replace if there is an open or short If the transmission sub lead.

Connected state of connector If there is a malfunction, repair it and connect it the sidestand. If the transmission Inspect the coupler for any pins that may securely. Main wiring harness ECU coupler reinstated by Check the locking condition of the coupler. ECU coupler illustration Indicate No. Defective sidestand switch Replace if defective. Code No. Installed state of sensor Check the installed area for looseness or Reinstated by turnpinching. Open or short circuit in wiring harness or Repair or replace if there is an open or short ON.

Connected state of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that may securely. Intake temperature sensor coupler Check the locking condition of the coupler.

Main wiring harness ECU coupler 4. Installed state of atmospheric pressure sen- Check the installed area for looseness or sor pinching.

Atmospheric pressure sensor coupler Main wiring harness ECU coupler. Oil temperature sensor coupler Check the locking condition of the coupler. Main wiring harness Black - Black Brown - Brown 3. Engine temperature sensor coupler Check the locking condition of the coupler. Electricity is not circulated to the decompression solenoid open or short circuit in thermistor is detected Used diagnostic code No. Installed state of decompression solenoid Check the installed area for looseness or Reinstated by turnpinching.

Decompression solenoid coupler Check the locking condition of the coupler. Malfunction in decompression solenoid Replace if defective.

Reinstated by turning the main switch Check the installed area for looseness or ON however, the pinching. Main wiring harness ECU coupler. Defective linear control valve Check the operating sound or that the warning light is on 3 times with engine stop switch ON. Open or short circuit in wiring harness or sub lead. Reinstatement method Perform diagnostic code 54 to check the operation of the linear control valve.

Main wiring harness linear control valve couCheck the locking condition of the coupler. Installed state of linear control valve Check the installed area for looseness or pinching. Open or short circuit in wiring harness or Repair or replace if there is an open or short Reinstated by turnsub lead. Main wiring harness oil temperature sensor Check the locking condition of the coupler.

Lean angle cut-off switch coupler Main wiring harness ECU coupler. Speed sensor coupler Check the locking condition of the coupler. Neutral switch coupler Check the locking condition of the coupler. Main wiring harness ECU coupler Faulty shift drum neutral detection area.

If there is no malfunction with the fuel injection system relay, replace the ECU. Fuel injection system relay coupler ECU coupler. When this malfunction is detected in the ECU, the fault code number might not appear on the meter. Diagnosis mode troubleshooting 2 self-diagnostic malfunction not detected Troubleshooting the sensors and actuator with no malfunctions detected, and special indications Even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self-diagnostic function, they can be inspected in the diagnosis mode.

Basic procedure Check the condition and the symptom of the malfunction of the motorcycle. Check the errors displayed on the meter. Estimate the area of the malfunction by referring to the troubleshooting details. If there is a diagnostic code number for the inspection method for the probable location of the malfunction, check the operating condition of the affected sensor or actuator in the diagnosis mode.

Using the results of the diagnosis mode inspection as reference, estimate the cause of the malfunction and carry out the inspection and repair of the affected area. Troubleshooting details Symptom Probable malfunction area. The engine trouble warning light does not illuminate when the start switch is pressed.

Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode, and in case the area of the malfunction has been narrowed down in the inspection method 1 indicated on the left. Defective: replace. Engine cannot be started or difficult to start. Fuel is not supplied to the cylinder. Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode, and in case the are of the malfunction has been narrowed down in the inspection method 1 given on the left.

Malfunction in the headlight relay Malfunction in the headlight Open or short circuit in the headlight wiring harness Malfunction in the handlebar switch Open circuit in the headlight bulb. Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode, and in case the area of the malfunction has been narrowed down in the inspection method 1. Check the operation of the headlight. Check the headlight relay. Defective: replace Inspect the wiring harness and the couplers for continuity.

Inspect the headlight bulb. Blown bulb: replace Check the headlight relay contact point for continuity. Defective: replace Check the handlebar switch. Defective: repair or replace Inspect the wiring harness and the couplers for continuity. Defective: repair or replace. No signals are received from the ECU. Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode, and in case the area of the malfunction has been narrowed down in the inspection method 1 given on the left.

No signals are received from the ECU within the specified duration. Data from the ECU cannot be received correctly. Non-registered data has been received from the meter. Sidestand switch does not function the engine does not stop when the stand is extended. Inspect the sidestand switch.

Engine trouble warning light blinks while the start switch is being pressed to warn that the engine is unable to start. Malfunction in Fuel injection system relay Open circuit in wiring harness Disconnected battery Defective crankshaft position sensor See page Defective sidestand switch See page Tripped lean angle cut-off switch See page , ECU memory check error.

Inspect the coil side of the relay unit. Defective: replace Inspect the wiring harness and couplers for continuity. Inspect the contact side of the fuel relay unit. Defective: replace or recharge Inspect and repair the applicable area of the malfunction. Throttle position sensor coupler A. Wash the throttle body in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution.

Blow out all of passages with compressed air. Remove the air duct. Remove the fuel hose end clamp 1. Disconnect the fuel hose 2 from the fuel injection pipe 3. Connect the mity vac 4 onto the pipe 5 onto the pressure regulator. Connect the fuel pressure adapter 6 to the pressure gauge 7.

Connect the fuel pressure adapter between the fuel hose 2 and fuel injection pipe 3. Start the engine. Measure the fuel pressure.

Fuel pressure kPa 3. Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. Normally, the air cut-off valve is open to allow fresh air to flow into the exhaust port. During sudden deceleration the throttle valve suddenly closes , negative pressure is generated and the air cut-off valve is closed in order to prevent after-burning.

Additionally, at high engine speeds and when the pressure decreases, the air cut-off valve automatically closes to guard against a loss of performance due to self-EGR. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the coupler terminal slots 1.

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A downloadable Yamaha Road Star Silverado Midnight repair manual is a digital book e-book that contains guidelines and instructions, and all you need to know about how to fix and sort out your two-wheeled motor vehicle.

This easy to use e-manual is downloadable in a pdf format and easily accessible by anyone. Download it to a smartphone, tablet or computer. The downloadable Yamaha Road Star Midnight Silverado motorcycle repair manual contains a detailed guide and instruction on everything about a motorcycle. Having a handy Yamaha Road Star Midnight Silverado motorcycle repair manual is like having an everywhere you go life-saver that functions optimally, weighs nothing, and costs nothing. This downloadable repair manual is useful because, for one, it provides instant help on easy to fix problems like troubleshooting, saving you the stress of a repair trip down to the local repair shop at every instant.

It provides and equips users with all the knowledge necessary relating to their two-wheeled vehicle in the easiest way possible with easy to understand language. It gives in-depth information on maintenance necessities and maintenance procedures, from the easiest to the toughest ones. It provides step-by-step instruction on repairs from the parts necessary, the repair methods, and the outcome.

It saves users from unnecessary hefty expenses that can easily be fixed without needing a repair shop trip, amongst other things.

Yamaha Road Star Midnight Silverado two-wheeled lovers who enjoy to have their vehicles running at optimum level need always to have a means of caring for these machines. Save my name, email, and website in this browser for the next time I comment. Im not sure if I need a specific manual for a Yamaha Road Star VX I cant find the model number sticker however I do have the vin that is on the sticker of the front fork.

Have an account? Sign In Now. Remember Me! Don't have account, Sign Up Here. Forgot Password Lost your password? You must login to ask question. Please briefly explain why you feel this question should be reported. Belt tension gauge YM This tool is used to measure the drive belt slack. YM This tool is used to check the ignition system components. Valve adjuster YM This tool is used to adjust the valve clearance.

Universal clutch holder YM This tool is used to hold the clutch boss when removing or installing the clutch boss nut. Primary sheave holder. This tool is used to hold the generator rotor when removing or installing the generator rotor bolt, generator shaft bolt or crankshaft position sensor rotor bolt.

Piston pin puller. YU This tool is used to remove the piston pins. Pocket tester YU This tool is used to check the electrical system. YU This gauge is needed for throttle bodies synchronization. YU This tool is used to loosen or tighten the steering stem ring nuts.

Oil filter wrench YU This tool is needed to loosen or tighten the oil filter cartridge. Inductive tachometer YUA This tool is used for check engine speed. This sealant is used to seal two mating surfaces e. Pressure gauge Oil pressure adaptor E. Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet with oil and a full fuel tank Dry without oil and fuel Gross vehicle weight ratio GVWR Bias weight dry front Bias weight dry rear Maximum load total of cargo, rider, passenger, and accessories.

Quantity Total amount Engine Oil tank Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve opening pressure Oil temperature. Air-cooled, 4-stroke, OHV 1, cm3 Outer rotor to oil pump housing clear- 0.

Gear drive Valve lifters Valve lifter outside diameter Valve lifter case inside diameter Valve lifter-to-valve lifter case clearance Valve push rods Valve push rod 1 length Valve push rod 2 length Valve push rod runout Cylinders Material Sleeve type Bore Max. Aluminum alloy Ceramic composite plated Limit Spring rate K1 Spring rate K2 Spring stroke K1 Spring stroke K2 Optional spring available Fork oil Recommended oil Quantity each front fork leg Level from the top of the outer tube and damper rod, with the outer tube fully compressed, and without the fork spring Inner tube outer diameter.

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads.

Components should be at room temperature. Cover Cover Oil tank left cover Oil tank left cover Oil strainer Transfer gear case Transfer gear case cover Transfer gear oil checking bolt Transfer gear oil pump cover Transfer gear oil pump Drive sprocket case Drive sprocket case.

Drive sprocket cover Shift arm Shift rod locknut Shift shaft spring stopper Shift drum assembly Shift drum assembly plate Stopper lever Neutral switch Speed sensor Intake air pressure sensor Intake air temperature sensor Oil temperature sensor Oil gallery bolt Oil gallery bolt Oil gallery bolt.

Damper rod assembly bolt Reflector bracket front Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Rear brake bracket and brake pedal Shift shaft and shift pedal. NOTE: 1. First, tighten the ring nut approximately 52 Nm 5. Retighten the ring nut to specification. CHASSIS Lubrication point Steering bearings and bearing races upper and lower Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal right and left Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal Rear footrest pivot Sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt, contact surface Clutch lever pivot bolt, contact surface Swingarm pivot shaft Swingarm pivot bearing Swingarm pivot oil seal Relay arm bearing inner Rear shock absorber bearing inner Connecting rod bearing inner.

Fit the starter motor lead and sidestand switch lead into the groove in the frame, and then fasten them with a plastic locking tie. Canister California only 1 Canister charge hose 2 Canister purge hose 3 Starter motor lead 4 Canister 5 Fuel tank drain hose 6 Regulator lead 7 Horn lead 8 Rear brake light switch lead. If followed, these preventive maintenance procedures will ensure more reliable vehicle 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. See page NOTE: From 24, mi 37, km or 36 months, repeat the maintenance intervals starting from 4, mi 7, km or 6 months.

Regularly check the brake fluid levels and fill the reservoirs as required. However, there are times that the valve clearance is needed to be adjusted manually.

If this is the case, adjust the clearance of the two maladjusted or worn valves, of a rocker arm, with the adjusting screw. Check if the valve clearance b on the adjusting screw 2 side is within specification.

Disconnect: spark plug caps 1 cylinder head breather hose 2 oil tank breather hose 3 Remove: spark plugs cylinder head covers upper gaskets dowel pins. Piston 1 TDC rear cylinder a. Turn the crankshaft counterclockwise. Check the camshaft drive gear mark c position and camshaft driven gear mark d position as shown. If the marks are not aligned, turn the crankshaft counterclockwise degrees and recheck step b. Measure the valve clearance with a thickness gauge. Piston 2 TDC front cylinder a.

Turn the crankshaft counterclockwise from the piston 1 TDC by degrees. Loosen the locknut 1. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. Turn the adjusting screw 3 in direction a or b with the valve adjuster until the specified valve clearance is obtained.

Valve adjuster YM Measure the valve clearance again. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

Note the following points. Remove: hose 1 hose 2 Install: carburetor synchronizer inductive tachometer onto the spark plug lead of cylinder 1 Carburetor synchronizer YU Inductive tachometer YUA.

Start the engine and let it warm up for several minutes. With throttle body 1 as standard, adjust throttle body 2 using the air screw 1. NOTE: Rev the engine two or three times, each time for less than a second, and check the synchronization again. Vacuum pressure at engine idling speed 50 kPa mm Hg, Stop the engine and remove the measuring equipment. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Remove the seat and fuel tank.

Loosen the locknut 2 on the decelerator cable. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.

Tighten the locknut 2. Loosen the locknut 4 on the accelerator cable. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.

Direction a. Tighten the locknut 4. 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. Handlebar side a. Loosen the locknut 6. Turn the adjusting nut 7 in direction c or d until the specified throttle cable free play is obtained. Direction c. After adjusting the throttle cable free play, start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change.

Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. Normal color is medium-to-light tan. Spark plug gap 0. Make sure all connections are tight and free of corrosion. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Check that the mark a is within the required firing range b on the timing. NOTE: The ignition timing is not adjustable.

NOTE: Insufficient compression pressure will result in a loss of performance. Start the engine, warm it up for several minutes, and then turn it off.

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. Compression pressure at sea level Minimum 1, kPa With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

To prevent sparking, ground all spark plug leads before cranking the engine. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. Compression pressure with oil applied into the cylinder Reading. Stand the motorcycle on a level surface. NOTE: Do not screw the dipstick in when inspecting the oil level.

Therefore, do not add any chemical additives. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. Place a container under the engine oil drain bolt. If the oil filter cartridge is also to be replaced, perform the following procedure. Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.

Tighten the new oil filter cartridge to specification with an oil filter wrench. Stop the engine, and then pour in the remainder of the specified amount. When pouring engine oil into the crankcase, pour it into the hole of the removed bolt 1. Slightly loosen the oil gallery bolt 1. 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 off so that it will not seize.

Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Start the engine after solving the problem s and check the engine oil pressure again. Tighten the oil gallery bolt to specification. When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine.

Install: checking bolt 8 Nm 0. Place a container under the transfer gear oil drain bolt. Pull the boot 1 off. Loosen the locknut 2. Turn the adjusting bolt 3 in direction a or b until the specified clutch cable free play is obtained. Tighten the locknut. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. Engine side a. Loosen the locknut 4.

Turn the adjusting bolt 5 in direction c or d until the specified clutch cable free play is obtained. 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 throttle body tuning, leading to poor engine performance and possible overheating. Make sure the breather hoses are routed correctly. Front exhaust pipe nut 4 20 Nm 2. Turn the adjusting screw 2 in direction a or b until the specified brake lever free play is obtained.

A soft or spongy feeling in the brake lever 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. After adjusting the brake lever free play, make sure there is no brake drag.

Brake pedal position from the top of the rider footrest to the top of the brake pedal 80 mm 3. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. After adjusting the brake pedal position, check that the end of the adjusting bolt c is visible through the hole d. A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system.

After adjusting the brake pedal position, make sure there is no brake drag. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. Operate the brake. Brake pad wear limit a 0. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

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. Hold the motorcycle upright and apply the brake several times. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

Install the diaphragm brake master cylinder reservoir or brake fluid reservoir. Connect a clear plastic hose 1 tightly to the bleed screw 2. Place the other end of the hose into a container. Slowly apply the brake several times. Fully pull the brake lever or fully press down the brake pedal and hold it in position. 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.

Tighten the bleed screw and then release the brake lever or brake pedal. Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose. Tighten the bleed screw to specification.

After bleeding the hydraulic brake system, check the brake operation. Loosen both locknuts 1. Turn the shift rod 2 in direction b or c to obtain the correct shift pedal position. Direction b. Tighten both locknuts. Make sure the installed shift rod length is within specification.

A drive belt that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive belt slack within the specified limits.

NOTE: Measure the drive belt slack when the engine is cold, and when the drive belt is dry. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated. Use them as a standard for measuring the drive belt slack. Turn both adjusting bolts 2 in direction a or b until the specified drive belt slack is obtained.

NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5. NOTE: Set the torque wrench at a right angle to the spanner wrench. 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. Install the rubber washer 3. Install the upper ring nut 2. 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.

Install the lock washer 1. NOTE: Make sure the lock washer tabs sit correctly in the ring nut slots. Hold the motorcycle upright and apply the front brake.

Uneven adjustment can result in poor handling and loss of stability. Never go beyond the maximum or minimum adjustment positions. Adjusting positions a Minimum: Never turn the spring preload adjusting nut beyond the maximum or minimum setting.

It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. Minimum tire tread depth 1. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.

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. New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately km should be traveled at normal speed before any high-speed riding is done. Never attempt to make any repairs to the wheel.

NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. Recommended lubricant 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 lubricating device. Recommended lubricant Lithium-soap-based grease.

Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Get immediate medical attention. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably.

Therefore, take special care when charging the battery. 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 measuring the voltage at the battery terminals. Connect a pocket tester to the battery terminals. Check the charge of the battery, as shown in the charts and the following example. Example c. If charging has to be done with the battery mounted on the motorcycle, disconnect the negative battery lead from the battery terminal.

A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. Hot batteries can explode! Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be overcharged. If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

Set the timer to the charging time determined by the opencircuit voltage. If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Under This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended. Charger Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Connect the pocket tester to the fuse and check the continuity. Pocket tester YU b. Install a new fuse of the correct amperage rating. Set on the switches to verify if the electrical circuit is operational. If the fuse immediately blows again, check the electrical circuit.

Never use a fuse with an amperage rating 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. Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 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. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi.

Reflector bracket left and right Brake hose holder Reflector left and right Brake caliper left and right Front fork guard left and right Wheel axle pinch bolt Front wheel axle. Do not attempt to straighten a bent wheel axle. Radial wheel runout limit 1.

Clean the outside of the front wheel hub. 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. Remove the wheel bearings 3 with a general bearing puller. Install the new wheel bearings and oil seals in the reverse order of disassembly.

Do not contact the wheel bearing inner race 4 or balls 5. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal. Brake disc deflection limit maximum Front: 0.

Place the motorcycle on a suitable stand so that the wheel is elevated. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface.

Measure the deflection 1. Brake disc thickness limit minimum Front: 4. Remove the brake disc. Rotate the brake disc by one bolt hole. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. If the brake disc deflection cannot be brought within specification, replace the brake disc.

Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. NOTE: When installing the front fork guards, make sure that there is not dirt between the guard and the front fork. Spin the front wheel. Release the front wheel.

Repeat steps d through f several times until all the marks come to rest at the same spot. NOTE: Start with the lightest weight. If the heavy spot does not stay in that position, install a heavier weight. Repeat steps b and c until the front wheel is balanced. Turn the front wheel and make sure it stays at each position shown.

If the front wheel does not remain stationary at all of the positions, rebalance it. Remarks Remove the parts in the order listed. For installation, reverse the removal procedure. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Remove the self-locking nuts and the rear wheel pulley. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the pulley.

Install the new rear wheel pulley. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. Install the rear wheel pulley with its wider spokes situated on top of the rear wheel spokes. NOTE: Temporarily tighten the wheel axle nut. The following procedure applies to both of the front brake calipers.

Disc brake components rarely require disassembly. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. Brake pad wear limit 0. Put the other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Tighten the bleed screw.

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 rotation. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger. Install a new brake pad shim 3 onto each new brake pad 4. Install new brake pads. For assembly, reverse the disassembly procedure.

Brake master cylinder bracket Rear brake light switch Horn 1 connector Right footrest assembly right. NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

Recommended brake fluid DOT 4. Proper brake hose routing is essential to insure safe motorcycle operation. Correct if necessary. When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a onto brake master cylinder bracket, as shown. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

Secure the right side brake caliper pistons with a piece of wood a. Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper. Remove the brake caliper piston seals. Repeat the previous steps to force out the right side pistons from the brake caliper.

Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper. Be careful not to get injured when the pistons are expelled from the brake caliper. When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper.

Remove: brake caliper Install: brake pad springs brake pad brake caliper brake caliper retaining bolts T. Front fender Upper bracket pinch bolt Cap bolt Turn signal light bracket pinch bolt Lower bracket pinch bolt Front fork leg. The following procedure applies to both of the front fork legs. Loosen: upper bracket pinch bolts 1 cap bolt 2 turn signal light bracket pinch bolt 3 lower bracket pinch bolts 4. Before loosening the upper and lower bracket pinch bolts and turn signal light bracket pinch bolt, support the front fork leg.

Press down on the spacer with the fork spring compressor 4. Install the rod holder 5 between the nut 3 and the spacer 2. Spring free length mm 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: While holding the damper rod assembly with the damper rod holder 2, tighten the damper rod assembly bolt.

Make sure the numbered side of the oil seal faces down. Fully compress the front fork leg. Other oils may have an adverse effect on front fork performance. 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. NOTE: Be careful not to stroke the outer tube over mm 8.

If the outer tube is stroke more than mm 8. 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.

Front fork leg oil level from the top of the outer tube and damper rod, with the outer tube fully compressed, and without the spring mm 3. Remove the rod puller. Install the nut 1. Install the rod puller onto the damper rod.

Rod puller YM d. Install the fork spring, spring seat, and spacer. Press down on the spacer with the fork spring compressor 6. Pull up the rod puller and install the rod holder between the nut 1 and the spacer 4. Install the nut 1 and position it as specified b. Distance b Hold the nut and tighten the cap bolt until it comes into contact with the nut.

Hold the cap bolt and tighten the nut to specification. The fork spring is compressed. Always use a new cap bolt O-ring. NOTE: Make sure the outer fork tube is flush with the top of the upper bracket. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: Align the match marks a on the handlebar with the upper surface of the lower handlebar holder. Apply a thin coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar.

Wipe off any excess rubber adhesive with a clean rag. Do not touch the handlebar grip until the rubber adhesive has fully dried.

Front fork legs Steering stem nut Upper bracket Cable guide Headlight bracket Brake hose bracket Brake hose joint Turn signal light bracket assembly. Lower bracket Lower bearing Lower bearing cover Upper bearing cover Upper bearing Bearing outer race. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.

Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Temporarily tighten the lower bracket pinch bolts. Adjusting bolt 2 Locknut 2 Lower drive belt cover plate 1 Spacer 1 Lower drive belt cover 1 Horn 2 coupler 1 Disconnect. Horn 2 1. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information.

The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. High heat can cause an explosion due to excessive gas pressure. Rear shock absorber damage will result in poor damping performance. If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play at the end of the swingarm 1 mm 0. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.

Wipe the drive belt with a clean cloth. Put the drive belt in a mixture of mild detergent and water. Then, remove any dirt from the drive belt. Remove the drive belt from the mixture and rinse it off with clean water. Then, let the drive belt thoroughly dry. Install the drive belt facing the same way it was removed. Do not twist the drive belt when installing it. NOTE: When tightening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move. Remarks Drain.

NOTE: Place a suitable stand under the frame and engine. Upper mounting bolt Upper mounting bracket bolt Upper mounting Self-locking nut Front mounting bolt Front engine bracket self-locking nut Front engine bracket Front engine bracket bolt Self-locking nut Upper rear mounting bolt. Install: self-locking nut 5, 6 rear engine bracket left 7 rear engine bracket right 8 upper rear mounting bolt 9 self-locking nut 0 front engine bracket A front mounting bolt B self-locking nut C upper engine bracket D upper mounting bolts E.

Turn the crankshaft clockwise. Rocker arm inside diameter Rocker arm shaft outside diameter Above 0. Rocker arm to rocker arm shaft clearance 0. Valve lifter outside diameter Valve lifter case inside diameter Valve lifter-to-valve lifter case clearance 0.

Fill a container with kerosene and place the valve lifter into the container as shown. Pump the plunger side of the valve lifter with a press a number of times to let in kerosene. Start the engine and warm it up. Stop the engine. Remove the camshaft sprocket cover. Rotate the camshaft until the punch mark 1 on the camshaft driven gear aligns with the punch mark on the camshaft drive gear as shown. This is the condition in which piston 1 is at top dead center TDC.

With piston 1 at TDC, count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown. When these marks align between the centers of the camshaft drive and driven gears, the corresponding valve lifter is at its highest point. Rotate the crankshaft unit the mark on the camshaft driven gear for the valve lifter to be bled aligns with the camshaft drive gear as shown.

Example: For bleeding the cylinder 2 intake valve lifter, align mark 2 as shown. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lifter to bleed.

The illustration is viewed from the right side of the motorcycle. Therefore, be sure to install them in the proper position. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1 10 Nm 1. Remove: front cylinder camshaft end cover camshaft drive gear 1 camshaft driven gear 2 straight keys. NOTE: Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase. After all of the bolts are fully loosened, remove them.

Camshaft lobe dimension limit Intake camshaft a Camshaft journal diameter crankcase side Camshaft journal diameter camshaft cover side Crankcase hole inside diameter Camshaft cover hole inside diameter NOTE: Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter.

Camshaft to crankcase clearance 0. NOTE: Calculate the clearance by subtracting the camshaft journal diameter camshaft cover side from the camshaft cover hole inside diameter. Camshaft to camshaft cover clearance 0. The teeth of both camshaft driven gears must be aligned for installation. Maximum cylinder head warpage 0. Place a straightedge and a thickness gauge across the cylinder head.

Measure the warpage. If the limit is exceeded, resurface the cylinder head as follows. NOTE: To ensure an even surface, rotate the cylinder head several times. The following procedure applies to both cylinders.

NOTE: Before removing the internal parts of the cylinder head e. Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal. Remove: upper spring seat 1 outer valve spring 2 inner valve spring 3 valve 4 valve stem seal 5 lower spring seat 6. NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. Valve-stem-to-valve-guide clearance Intake 0. Remove the valve guide with the valve guide remover 1. Install the new valve guide with the valve guide installer 2 and valve guide remover 1.

After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.

NOTE: After replacing the valve guide, reface the valve seat. Valve margin thickness 0. Valve seat width Intake 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed.

Do not let the lapping compound enter the gap between the valve stem and the valve guide. Apply molybdenum disulfide oil onto the valve stem. 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. Apply a fine lapping compound to the valve face and repeat the above steps.

After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. Valve spring free length Intake valve spring Compressed valve spring force installed Intake and exhaust inner valve spring 6. Spring tilt limit Intake and exhaust inner valve spring 2.

Install: lower spring seat 1 valve stem seal 2 valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 into the cylinder head. Valve spring compressor set YM 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Do not use a hammer to drive the piston pin out. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 4.

NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Then, find the average of the measurements. If out of specification, replace the cylinder, and the piston and piston rings as a set. If out of specification, replace the piston and piston rings as a set.

Calculate the piston-to-cylinder clearance with the following formula. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0. Piston ring end gap Top ring 0. Piston pin outside diameter Piston pin bore diameter in the piston Install: dowel pins 1 cylinder gasket 2 New Lubricate: piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil.

NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. Straighten the lock washer tab. NOTE: There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip 4 and disassemble the built-in damper unless there is serious clutch chattering. NOTE: Measure the friction plate at four places.

Clutch plate warpage limit 0. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. NOTE: While holding the generator rotor 6 with the primary sheave holder 7, tighten the crankshaft position sensor rotor bolt.

NOTE: While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss nut. Plastic locking tie Plastic band Rear brake light switch coupler Horn 1 connectors Rider footrest assembly right Stator coil assembly coupler Oil delivery pipe. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch.

NOTE: While holding the generator rotor 2 with the primary sheave holder 3, tighten the generator rotor bolt. Inner rotor-to-outer rotor tip clearance 0. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.

Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Install: engine oil pump driven gear 1 engine oil pump driven gear stopper 2 oil delivery pipe 3 bolts 4 10 Nm 1.

Install: oil pump housing 1 oil seals 2 oil pump outer rotor 2 3 oil pump inner rotor 2 4 pin 5 oil pump shaft 6 pins 7 oil pump housing cover 2 8.

NOTE: When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor.