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Table of Contents
- 4. How to use this manual
- 5. SYMBOLS
- 7. Table of Contents
- 9. GENERAL INFORMATION
- 10. IDENTIFICATION
- 11. FEATURES
- 12. FI SYSTEM
- 13. YCC-T (Yamaha Chip Controlled Throttle)
- 16. INSTRUMENT FUNCTIONS
- 21. IMPORTANT INFORMATION
- 22. BEARINGS AND OIL SEALS
- 23. CHECKING THE CONNECTIONS
- 24. SPECIAL TOOLS
- 31. SPECIFICATIONS
- 32. GENERAL SPECIFICATIONS
- 33. ENGINE SPECIFICATIONS
- 41. CHASSIS SPECIFICATIONS
- 44. ELECTRICAL SPECIFICATIONS
- 47. TIGHTENING TORQUES
- 48. ENGINE TIGHTENING TORQUES
- 52. CHASSIS TIGHTENING TORQUES
- 56. LUBRICATION POINTS AND LUBRICANT TYPES
- 58. CHASSIS
- 60. LUBRICATION SYSTEM CHART AND DIAGRAMS
- 62. LUBRICATION DIAGRAMS
- 74. COOLING SYSTEM DIAGRAMS
- 78. CABLE ROUTING
- 93. PERIODIC CHECKS AND ADJUSTMENTS
- 96. PERIODIC MAINTENANCE
- 98. ENGINE
- 101. SYNCHRONIZING THE THROTTLE BODIES
- 102. ADJUSTING THE EXHAUST GAS VOLUME
- 103. ADJUSTING THE THROTTLE CABLE FREE PLAY
- 104. MEASURING THE COMPRESSION PRESSURE
- 105. CHECKING THE ENGINE OIL LEVEL
- 106. CHANGING THE ENGINE OIL
- 108. MEASURING THE ENGINE OIL PRESSURE
- 109. REPLACING THE AIR FILTER ELEMENT
- 110. CHECKING THE THROTTLE BODY JOINTS
- 111. CHECKING THE EXHAUST SYSTEM
- 112. CHECKING THE COOLANT LEVEL
- 113. CHECKING THE COOLING SYSTEM
- 114. CHANGING THE COOLANT
- 116. CHASSIS
- 117. CHECKING THE BRAKE FLUID LEVEL
- 118. CHECKING THE FRONT BRAKE HOSES
- 119. BLEEDING THE HYDRAULIC BRAKE SYSTEM
- 120. ADJUSTING THE SHIFT PEDAL
- 121. LUBRICATING THE DRIVE CHAIN
- 123. CHECKING THE FRONT FORK
- 125. ADJUSTING THE REAR SHOCK ABSORBER ASSEMB...
- 127. CHECKING THE TIRES
- 128. CHECKING THE WHEELS
- 129. CHECKING AND LUBRICATING THE CABLES
- 137. GENERAL CHASSIS
- 142. FRONT WHEEL
- 143. ASSEMBLING THE FRONT WHEEL
- 144. CHECKING THE FRONT BRAKE DISCS
- 146. REAR WHEEL
- 149. REMOVING THE REAR WHEEL
- 152. FRONT BRAKE
- 157. INTRODUCTION
- 158. REPLACING THE FRONT BRAKE PADS
- 159. REMOVING THE FRONT BRAKE CALIPERS
- 160. ASSEMBLING THE FRONT BRAKE CALIPERS
- 161. REMOVING THE FRONT BRAKE MASTER CYLINDER
- 162. INSTALLING THE FRONT BRAKE MASTER CYLIND...
- 169. REAR BRAKE
- 170. REMOVING THE REAR BRAKE CALIPER
- 171. CHECKING THE REAR BRAKE CALIPER
- 172. INSTALLING THE REAR BRAKE CALIPER
- 173. REMOVING THE REAR BRAKE MASTER CYLINDER
- 175. HANDLEBARS
- 177. REMOVING THE HANDLEBARS
- 179. FRONT FORK
- 182. REMOVING THE FRONT FORK LEGS
- 183. CHECKING THE FRONT FORK LEGS
- 184. ASSEMBLING THE FRONT FORK LEGS
- 187. INSTALLING THE FRONT FORK LEGS
- 189. STEERING HEAD
- 192. REMOVING THE LOWER BRACKET
- 194. REAR SHOCK ABSORBER ASSEMBLY
- 196. HANDLING THE REAR SHOCK ABSORBER
- 197. CHECKING THE CONNECTING ARM AND RELAY AR...
- 199. SWINGARM
- 201. REMOVING THE SWINGARM
- 202. INSTALLING THE SWINGARM
- 209. ENGINE
- 212. ENGINE REMOVAL
- 217. INSTALLING THE ENGINE
- 218. CAMSHAFTS
- 220. REMOVING THE CAMSHAFTS
- 223. INSTALLING THE CAMSHAFTS
- 226. CYLINDER HEAD
- 227. REMOVING THE CYLINDER HEAD
- 230. VALVES AND VALVE SPRINGS
- 232. CHECKING THE VALVE SEATS
- 233. CHECKING THE VALVE SPRINGS
- 234. CHECKING THE VALVE LIFTERS
- 237. GENERATOR AND STARTER CLUTCH
- 239. REMOVING THE GENERATOR
- 240. INSTALLING THE GENERATOR
- 241. PICKUP ROTOR
- 242. REMOVING THE PICKUP ROTOR
- 244. ELECTRIC STARTER
- 246. CHECKING THE STARTER MOTOR
- 247. ASSEMBLING THE STARTER MOTOR
- 248. CLUTCH
- 252. REMOVING THE CLUTCH
- 253. CHECKING THE CLUTCH SPRINGS
- 254. CHECKING THE CLUTCH HOUSING
- 255. CHECKING THE OIL PUMP DRIVE SPROCKET AND...
- 258. SHIFT SHAFT
- 260. CHECKING THE SHIFT SHAFT
- 261. OIL PUMP
- 264. REMOVING THE OIL PAN
- 265. CHECKING THE OIL PIPES
- 266. CRANKCASE
- 268. DISASSEMBLING THE CRANKCASE
- 271. CONNECTING RODS AND PISTONS
- 272. CHECKING THE PISTON RINGS
- 273. CHECKING THE PISTON PINS
- 274. CHECKING THE CONNECTING RODS
- 275. INSTALLING THE CONNECTING RODS AND PISTO...
- 278. CRANKSHAFT
- 279. REMOVING THE CRANKSHAFT JOURNAL BEARINGS
- 281. INSTALLING THE CRANKSHAFT
- 287. TRANSMISSION
- 288. CHECKING THE TRANSMISSION
- 289. INSTALLING THE TRANSMISSION
- 291. COOLING SYSTEM
- 292. RADIATOR
- 294. CHECKING THE RADIATOR
- 295. OIL COOLER
- 297. CHECKING THE OIL COOLER
- 298. THERMOSTAT
- 299. CHECKING THE THERMOSTAT
- 300. WATER PUMP
- 301. CHECKING THE WATER PUMP
- 303. FUEL SYSTEM
- 304. FUEL TANK
- 305. REMOVING THE FUEL TANK
- 306. INSTALLING THE FUEL TANK
- 307. AIR FILTER CASE
- 309. REMOVING THE FUEL HOSE (PRIMARY INJECTOR...
- 311. THROTTLE BODIES
- 313. CHECKING THE PRIMARY INJECTORS
- 314. ADJUSTING THE THROTTLE POSITION SENSOR (...
- 316. AIR INDUCTION SYSTEM
- 320. CHECKING THE AIR INDUCTION SYSTEM
- 321. ELECTRICAL SYSTEM
- 324. IGNITION SYSTEM
- 327. TROUBLESHOOTING
- 330. ELECTRIC STARTING SYSTEM
- 332. STARTING CIRCUIT CUT-OFF SYSTEM OPERATIO...
- 334. TROUBLESHOOTING
- 337. CHARGING SYSTEM
- 338. CIRCUIT DIAGRAM
- 340. LIGHTING SYSTEM
- 342. TROUBLESHOOTING
- 344. SIGNALING SYSTEM
- 346. TROUBLESHOOTING
- 352. COOLING SYSTEM
- 354. TROUBLESHOOTING
- 356. FUEL INJECTION SYSTEM
- 358. ECU SELF-DIAGNOSTIC FUNCTION
- 359. SELF-DIAGNOSTIC FUNCTION TABLE
- 362. TROUBLESHOOTING METHOD
- 363. DIAGNOSTIC MODE
- 371. TROUBLESHOOTING DETAILS
- 396. FUEL PUMP SYSTEM
- 398. TROUBLESHOOTING
- 400. IMMOBILIZER SYSTEM
- 402. GENERAL INFORMATION
- 406. TROUBLESHOOTING
- 410. ELECTRICAL COMPONENTS
- 414. CHECKING THE SWITCHES
- 417. CHECKING THE BULBS AND BULB SOCKETS
- 418. CHECKING THE FUSES
- 419. CHECKING AND CHARGING THE BATTERY
- 422. CHECKING THE RELAYS
- 423. CHECKING THE TURN SIGNAL/HAZARD RELAY
- 424. CHECKING THE RELAY UNIT (DIODE)
- 425. CHECKING THE IGNITION COILS
- 426. CHECKING THE CRANKSHAFT POSITION SENSOR
- 427. CHECKING THE RECTIFIER/REGULATOR
- 428. CHECKING THE OIL LEVEL SWITCH
- 429. CHECKING THE SPEED SENSOR
- 430. CHECKING THE THROTTLE POSITION SENSOR
- 431. CHECKING THE FUEL PUMP
- 432. CHECKING THE ATMOSPHERIC PRESSURE SENSOR
- 433. CHECKING THE INTAKE AIR PRESSURE SENSOR
- 435. TROUBLESHOOTING
- 436. TROUBLESHOOTING
- 437. POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
- 438. OVERCOOLING
- 439. FAULTY LIGHTING OR SIGNALING SYSTEM
- 440. Wiring diagram
Page 1 of 444
Table of Contents
- 4. How to use this manual
- 5. SYMBOLS
- 7. Table of Contents
- 9. GENERAL INFORMATION
- 10. IDENTIFICATION
- 11. FEATURES
- 12. FI SYSTEM
- 13. YCC-T (Yamaha Chip Controlled Throttle)
- 16. INSTRUMENT FUNCTIONS
- 21. IMPORTANT INFORMATION
- 22. BEARINGS AND OIL SEALS
- 23. CHECKING THE CONNECTIONS
- 24. SPECIAL TOOLS
- 31. SPECIFICATIONS
- 32. GENERAL SPECIFICATIONS
- 33. ENGINE SPECIFICATIONS
- 41. CHASSIS SPECIFICATIONS
- 44. ELECTRICAL SPECIFICATIONS
- 47. TIGHTENING TORQUES
- 48. ENGINE TIGHTENING TORQUES
- 52. CHASSIS TIGHTENING TORQUES
- 56. LUBRICATION POINTS AND LUBRICANT TYPES
- 58. CHASSIS
- 60. LUBRICATION SYSTEM CHART AND DIAGRAMS
- 62. LUBRICATION DIAGRAMS
- 74. COOLING SYSTEM DIAGRAMS
- 78. CABLE ROUTING
- 93. PERIODIC CHECKS AND ADJUSTMENTS
- 96. PERIODIC MAINTENANCE
- 98. ENGINE
- 101. SYNCHRONIZING THE THROTTLE BODIES
- 102. ADJUSTING THE EXHAUST GAS VOLUME
- 103. ADJUSTING THE THROTTLE CABLE FREE PLAY
- 104. MEASURING THE COMPRESSION PRESSURE
- 105. CHECKING THE ENGINE OIL LEVEL
- 106. CHANGING THE ENGINE OIL
- 108. MEASURING THE ENGINE OIL PRESSURE
- 109. REPLACING THE AIR FILTER ELEMENT
- 110. CHECKING THE THROTTLE BODY JOINTS
- 111. CHECKING THE EXHAUST SYSTEM
- 112. CHECKING THE COOLANT LEVEL
- 113. CHECKING THE COOLING SYSTEM
- 114. CHANGING THE COOLANT
- 116. CHASSIS
- 117. CHECKING THE BRAKE FLUID LEVEL
- 118. CHECKING THE FRONT BRAKE HOSES
- 119. BLEEDING THE HYDRAULIC BRAKE SYSTEM
- 120. ADJUSTING THE SHIFT PEDAL
- 121. LUBRICATING THE DRIVE CHAIN
- 123. CHECKING THE FRONT FORK
- 125. ADJUSTING THE REAR SHOCK ABSORBER ASSEMB...
- 127. CHECKING THE TIRES
- 128. CHECKING THE WHEELS
- 129. CHECKING AND LUBRICATING THE CABLES
- 137. GENERAL CHASSIS
- 142. FRONT WHEEL
- 143. ASSEMBLING THE FRONT WHEEL
- 144. CHECKING THE FRONT BRAKE DISCS
- 146. REAR WHEEL
- 149. REMOVING THE REAR WHEEL
- 152. FRONT BRAKE
- 157. INTRODUCTION
- 158. REPLACING THE FRONT BRAKE PADS
- 159. REMOVING THE FRONT BRAKE CALIPERS
- 160. ASSEMBLING THE FRONT BRAKE CALIPERS
- 161. REMOVING THE FRONT BRAKE MASTER CYLINDER
- 162. INSTALLING THE FRONT BRAKE MASTER CYLIND...
- 169. REAR BRAKE
- 170. REMOVING THE REAR BRAKE CALIPER
- 171. CHECKING THE REAR BRAKE CALIPER
- 172. INSTALLING THE REAR BRAKE CALIPER
- 173. REMOVING THE REAR BRAKE MASTER CYLINDER
- 175. HANDLEBARS
- 177. REMOVING THE HANDLEBARS
- 179. FRONT FORK
- 182. REMOVING THE FRONT FORK LEGS
- 183. CHECKING THE FRONT FORK LEGS
- 184. ASSEMBLING THE FRONT FORK LEGS
- 187. INSTALLING THE FRONT FORK LEGS
- 189. STEERING HEAD
- 192. REMOVING THE LOWER BRACKET
- 194. REAR SHOCK ABSORBER ASSEMBLY
- 196. HANDLING THE REAR SHOCK ABSORBER
- 197. CHECKING THE CONNECTING ARM AND RELAY AR...
- 199. SWINGARM
- 201. REMOVING THE SWINGARM
- 202. INSTALLING THE SWINGARM
- 209. ENGINE
- 212. ENGINE REMOVAL
- 217. INSTALLING THE ENGINE
- 218. CAMSHAFTS
- 220. REMOVING THE CAMSHAFTS
- 223. INSTALLING THE CAMSHAFTS
- 226. CYLINDER HEAD
- 227. REMOVING THE CYLINDER HEAD
- 230. VALVES AND VALVE SPRINGS
- 232. CHECKING THE VALVE SEATS
- 233. CHECKING THE VALVE SPRINGS
- 234. CHECKING THE VALVE LIFTERS
- 237. GENERATOR AND STARTER CLUTCH
- 239. REMOVING THE GENERATOR
- 240. INSTALLING THE GENERATOR
- 241. PICKUP ROTOR
- 242. REMOVING THE PICKUP ROTOR
- 244. ELECTRIC STARTER
- 246. CHECKING THE STARTER MOTOR
- 247. ASSEMBLING THE STARTER MOTOR
- 248. CLUTCH
- 252. REMOVING THE CLUTCH
- 253. CHECKING THE CLUTCH SPRINGS
- 254. CHECKING THE CLUTCH HOUSING
- 255. CHECKING THE OIL PUMP DRIVE SPROCKET AND...
- 258. SHIFT SHAFT
- 260. CHECKING THE SHIFT SHAFT
- 261. OIL PUMP
- 264. REMOVING THE OIL PAN
- 265. CHECKING THE OIL PIPES
- 266. CRANKCASE
- 268. DISASSEMBLING THE CRANKCASE
- 271. CONNECTING RODS AND PISTONS
- 272. CHECKING THE PISTON RINGS
- 273. CHECKING THE PISTON PINS
- 274. CHECKING THE CONNECTING RODS
- 275. INSTALLING THE CONNECTING RODS AND PISTO...
- 278. CRANKSHAFT
- 279. REMOVING THE CRANKSHAFT JOURNAL BEARINGS
- 281. INSTALLING THE CRANKSHAFT
- 287. TRANSMISSION
- 288. CHECKING THE TRANSMISSION
- 289. INSTALLING THE TRANSMISSION
- 291. COOLING SYSTEM
- 292. RADIATOR
- 294. CHECKING THE RADIATOR
- 295. OIL COOLER
- 297. CHECKING THE OIL COOLER
- 298. THERMOSTAT
- 299. CHECKING THE THERMOSTAT
- 300. WATER PUMP
- 301. CHECKING THE WATER PUMP
- 303. FUEL SYSTEM
- 304. FUEL TANK
- 305. REMOVING THE FUEL TANK
- 306. INSTALLING THE FUEL TANK
- 307. AIR FILTER CASE
- 309. REMOVING THE FUEL HOSE (PRIMARY INJECTOR...
- 311. THROTTLE BODIES
- 313. CHECKING THE PRIMARY INJECTORS
- 314. ADJUSTING THE THROTTLE POSITION SENSOR (...
- 316. AIR INDUCTION SYSTEM
- 320. CHECKING THE AIR INDUCTION SYSTEM
- 321. ELECTRICAL SYSTEM
- 324. IGNITION SYSTEM
- 327. TROUBLESHOOTING
- 330. ELECTRIC STARTING SYSTEM
- 332. STARTING CIRCUIT CUT-OFF SYSTEM OPERATIO...
- 334. TROUBLESHOOTING
- 337. CHARGING SYSTEM
- 338. CIRCUIT DIAGRAM
- 340. LIGHTING SYSTEM
- 342. TROUBLESHOOTING
- 344. SIGNALING SYSTEM
- 346. TROUBLESHOOTING
- 352. COOLING SYSTEM
- 354. TROUBLESHOOTING
- 356. FUEL INJECTION SYSTEM
- 358. ECU SELF-DIAGNOSTIC FUNCTION
- 359. SELF-DIAGNOSTIC FUNCTION TABLE
- 362. TROUBLESHOOTING METHOD
- 363. DIAGNOSTIC MODE
- 371. TROUBLESHOOTING DETAILS
- 396. FUEL PUMP SYSTEM
- 398. TROUBLESHOOTING
- 400. IMMOBILIZER SYSTEM
- 402. GENERAL INFORMATION
- 406. TROUBLESHOOTING
- 410. ELECTRICAL COMPONENTS
- 414. CHECKING THE SWITCHES
- 417. CHECKING THE BULBS AND BULB SOCKETS
- 418. CHECKING THE FUSES
- 419. CHECKING AND CHARGING THE BATTERY
- 422. CHECKING THE RELAYS
- 423. CHECKING THE TURN SIGNAL/HAZARD RELAY
- 424. CHECKING THE RELAY UNIT (DIODE)
- 425. CHECKING THE IGNITION COILS
- 426. CHECKING THE CRANKSHAFT POSITION SENSOR
- 427. CHECKING THE RECTIFIER/REGULATOR
- 428. CHECKING THE OIL LEVEL SWITCH
- 429. CHECKING THE SPEED SENSOR
- 430. CHECKING THE THROTTLE POSITION SENSOR
- 431. CHECKING THE FUEL PUMP
- 432. CHECKING THE ATMOSPHERIC PRESSURE SENSOR
- 433. CHECKING THE INTAKE AIR PRESSURE SENSOR
- 435. TROUBLESHOOTING
- 436. TROUBLESHOOTING
- 437. POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
- 438. OVERCOOLING
- 439. FAULTY LIGHTING OR SIGNALING SYSTEM
- 440. Wiring diagram
File size: 23.51 MB
Created: March 10, 2023
Last updated: March 27, 2023
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