fzr400 19881989 PDF

Yamaha
FZR400
Service
Manual 1988-1989 Models
Downloaded from www.Manualslib.com manuals search engine

CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . l-l
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . ....... l-2

PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . ....... l-2
ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . ....... l-2
GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . ....... l-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . ....... l-3
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . ....... l-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... l-3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-4

FOR TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-5
FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-B
FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-9
CHAPTER 2.
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ENGINE................................................2- 4
CHASSIS...............................................2-11
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
GENERAL TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2-16
DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . 2-17
LUBRICATION DIAGRAM. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-20
COOLANT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
................................. . . . . . . . . . . . . 2-21
CABLE ROUTING

CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 3-1
MAINTENANCE INTERVALS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-l

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM . . . . . . . . .3-l
GENERAL MAINTENANCE/LUBRICATION . . . . . . . . . . . . . . . . . . . . . .3-2
COWLING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .3-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
EXUP CABLE ADJUSTMENT (For California only) . . . . . . . . . . . . . . . . 3-7
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
THROTTLE CABLE FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . 3-18
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . 3-21
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CLUTCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CARBURETOR JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CRANKCASE VENTILATION HOSE INSPECTION . . . . . . . . . . . . . . . . 3-28
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHASSIS ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
REAR BRAKE LIGHT SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . 3-33
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
AIR BLEEDlNG............................................3-3 4
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 3-40
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
TAIL/BRAKE BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-l

LOWER COWLING, CENTER COWLING,
UPPER COWLING AND TOP COVER. . . . . . . . . . . . . . . . . . . . . . . . . . .4-l
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-l
ENGINEOIL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.........4- 1
COOLANT.................................................4- 1
AIR FILTER CASE AND CARBURETOR., . . . . . . . . . . . . . . . . . . . . . . .4-l
RADIATOR................................................4- 2
MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
CLUTCH CABLE AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
LEADS....................................................4- 4
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

CYLINDER HEAD COVER, CAMSHAFT AND
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
CLUTCH..................................................4-13
A.C. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
OIL PUMP AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
OIL PAN AND OIL STRAINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
TRANSMISSION, SHIFTER AND SHIFT CAM. . . . . . . . . . . . . . . . . . . . 4-19
............................................. 4-20
CRANKSHAFT
VALVE PAD AND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
INNER ROTOR (OIL PUMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . 4-24
VALVE...................................................4-2 5
VALVE GUIDE . . . . . . . . I:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
VALVE SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
VALVE LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
CAMSHAFT, CAM CHAIN AND CAM SPROCKET . . . . . . . . . . . . . . . . .4-31

PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
CRANKSHAFT AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . 4-37
OlLPUMP.................................................4-4 1
PRlMARYDRlVE..........................................4-4 2
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
CLUTCH..................................................4-4 4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
RELIEF VALVE AND PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
BEARING AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
YAMAHA EXHAUST VARIABLE VALVE (For California only) . . . . . .4-48
ENGINE ASSEMBLY AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .4-49

INNER ROTOR (OIL PUMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
CONNECTING ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
VALVE PAD AND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
TRANSMISSION, SHIFTER AND SHIFT CAM . . . . . . . . . . . . . . . . . . . .4-56
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
OIL PAN AND OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
OIL PUMP AND SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60
A.C. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61
CLUTCH..................................................4-6 3
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65
PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67
CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70
CAM CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75
REMOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

CHAPTER 5.
COOLING SYSTEM
RADlATOR...................................................5- 1
REMOVAL.................................................5- 2
INSPECTION...............................................5- 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
WATER PUMP AND THERMOSTATIC VALVE. . . . . . . . . . . . . . . . . . . . . . . 5-6

REMOVAL.................................................5- 7
lNSPECTlON...............................................5- 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
CHAPTER 6.
CARBURETOR
............................................... 6-l
CARBURETOR
SECTIONVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
............................................ 6-5
DISASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-B
ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
........................................... 6-9 ,: i;
INSTALLATION
............................................. 6-10
ADJUSTMENT
CHAPTER 7.
CHASSIS
.............................................. 7-l
FRONT WHEEL.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-B
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-B
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

FRONT AND REAR BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
BRAKE PAD REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

REMOVAL................................................7-2 9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
lNSPECTlON..............................................7-3 1
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
STEERING HEAD AND HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

REMOVAL................................................7-3 8
lNSPECTlON..............................................7-4 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . . . . 7-47

HANDLING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
DISPOSAL NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
REMOVAL................................................7-4 9
lNSPECTlON..............................................7-5 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
DRIVE CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

REMOVAL................................................7-5 6
INSPECTION AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
INSTALL’ATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

CHAPTER 8.
ELECTRICAL
FZR400U/SUC CIRCUIT DIAGRAM ............................ 8-1
ELECTRICAL COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING OF SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

SWITCH CONNECTION AS SHOWN IN MANUAL . . . . . . . . . . . . . . . . . .8-5
CHECKING SWITCH FOR TERMINAL CONNECTION . . . . . . . . . . . . . .8-5
CHECKING OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

KINDS OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
CHECKING BULB CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-l 1

Cl RCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION . . . . . . . . . . . 8-13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

CIRCUITDIAGRAM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-3 3
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
SIGNALSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
SIGNAL SYSTEM CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69

Cl RCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
FUELSYSTEM................................................8.7 5
....................................... .8-75
CIRCUIT DIAGRAM
............................ 8.77
FUEL PUMP CIRCUIT OPERATION
FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-82

YAMAHA EXHAUST VARIABLE VALVE SYSTEM
(For California only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85
METER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89

REMOVAL................................................8-9 0
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE.. . . . . . . . . . . . . . . . . 9-4
FAULTY GEAR SHIFTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
OVERHEATING OR OVER-COOLING.. . . . . . . . . . I.. . . . . . . . . . . . . . . . . 9-6
FAULTY BRAKE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _. . . . 9-7
FRONT FORK OIL LEAKAGE/MALFUNCTION.. . . . . . . . . . . . . . . . . . . . . 9-7
INSTABLE HANDLING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FAULTY SIGNALS AND LIGHTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
FAULTY EXUP (For California only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-l 0

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PERIODIC INSPECTIONS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 6

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DRIVE C H A I N S L A C K A D J U S T M E N T . . . . . . . . . . . . . . . . . . . . . . . . 6
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REARWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STATIC WHEEL BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . 11
FRONT AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 21
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

MOTORCYCLE IDENTIFICATION
GENERAL
INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number @ is stemped
into the right side of the steering head.
Starting serial number:

FZR400A (Except for California):
JYA3BFEO * LA012101
FZR400SAC (For California):
I JYASFHCO * LA003101 J
NOTE:
The vehicle identification number is used to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your state.
ENGINE SERIAL NUMBER

The engine serial number @ is stamped into the
right side of the engine.
Starting serial number:

FZR400A (Except for California):
3BF-012101
FZR400SAC (For California):
I 3FH-003101 1
NOTE:
@The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
@Designs and specifications are subject to
change without notice.
FZRIQOOA FZ R400SAC

GENERAL SPECIFICATIONS JSPECII
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model FZR400A/FZR400SAC
Model Code Number: 3BF5 (FZR400A)
3FH3 (FZR400SAC)
Vehicle Identification Number: JYA3BFEO -X L A 0 1 2 1 0 1 (FZR400A)
JYA3FHCO +X- L A 0 0 3 1 0 1 (FZR400SAC)
Engine Starting Number: 3BF-012101 (FZR400A)
3FH-003101 (FZR400SAC)
Basic Weight:
With Oil and Full Fuel Tank 188 kg (414 lb) (FZR400A)
191 kg (421 lb) (FZR400SAC)
Tire: Front Rear
Type Tubeless Tubeless
Size 110/70R17-54H 140/60R 1 B-64H
Manufacture (Type) BRIDGESTONE BRIDGESTONE
(CYl5) (CY16)
DUNLOP DUNLOP
(K5lOF) (K510)
-2-

MAINTENANCE SPECIFICATIONS pqq
MAINTENANCE SPECIFICATIONS
CHASSIS
Model FZR400A/FZR400SAC
Front Suspension:
Front Fork Travel 130 mm (5.12 in)
Front Spring Free Length 412 mm (16.2 in)
< Limit > 408 mm (16.1 in)
Collar Length 160 mm (6.3 in)
Spring Rate: Kl 4.4 N/mm (0.5 kg/mm, 25.2 lb/in)
K2 6.6 N/mm (0.7 kg/mm, 37.5 lb/in)
Stroke Kl 0.0 - 90 mm (0.0 - 3.54 in)
K2 90 - 130 mm (3.54 - 5.12 in)
Optional Spring No
Oil Capacity 440 cm3 (15.5 Imp 02, 14.9 US oz)
Oil Level (Fully Compression) 92 mm (3.62 in)
Bellow the top of inner fork tube without
fork spring
Oil Grade Yamaha Fork Oil 10WT or equivalent
Front Disc Brake:
Type Dual
Disc Outside Diameter x Thickness 282 x 4 mm (11 .lO x 0.16 in)
Pad Thickness Inner 5.5 mm (0.22 in)
< Limit >* 0.5 mm (0.02 in)
Pad Thickness Outer 5.5 mm (0.22 in)
< Limit >* 0.5 mm (0.02 in)
.: ‘.I. . . , ‘,‘;:.‘;. . ;. .;: *
4
Master Cylinder Inside Diameter 15.87 mm (0.62 in)
Caliper Cylinder Inside Diameter 32.10 mm (1.26 in)
Brake Fluid Type DOT#4or DOT#3
-3-

MAINTENANCE SPECIFICATIONS -1
TIGHTENING TORQUE
-r
Part to be tightened
Front Axle and Outer Tube

Thread size
MI4x I . 5
-
Nm
Tightening torque
58
ma kg
5.8
ft. lb
42
T\
Rear Axle and Nut Ml6 x 1.5 107 10.7 77
Handlebar Crown and Inner Tube M8 x I.25 26 2.6 19
Handlebar Crown and Steering Stem M22 x 1.0 110 11.0 80
Brake Caliper (Front/Rear) MIOx 1.25 35 3.5 25
Bleed Screw and Brake Caliper M8 x 1.25 6 0.6 4.3
Brake Hose and Union Bolt MIOx 1.25 26 2.6 19
Front Master Cylinder and Master Cylinder Holder M6 x 1.0 9 0.9 6.5
Front Master Cylinder and Cylinder Cap M5 x 0.8 2 0.2 1.4
Front Fender and Outer Tube M6 x 1.0 6 0.6 4.3
Handlebar and Inner Tube M8 x 1.25 23 2.3 17
Engine Mounting: Front MlOx 1.25 55 5.5 40
Rear - Upper MlOx 1.25 55 5.5 40
Rear - Lower M8 x 1.25 45 4.5 32
Down Tube and Frame: Front MlOx I.25 60 6.0 43
Rear M8 x 1.25 33 3.3 24
Footrest Bracket and Frame Ml0 x 1.25 33 3.3 24
Pivot Axle and Nut Ml4x 1.5 90 9.0 65
Relay Arm and Frame MIOx 1.25 40 4.0 29
Arm and Swingarm Ml0 x 1.25 40 4.0 29
Arm and Relay Arm MlOx I.25 40 4.0 29
Rear Shock Absorber and Relay Arm MIOx I.25 40 4.0 29
Rear Shock Absorber and Frame Ml0 x 1.25 40 4.0 29
Footrest and Footrest Bracket Ml0 x 1.25 57 5.7 41
Rear Footrest Bracket and Frame M8 x 1.25 20 2.0 I4
Rear Master Cylinder and Rear Arm Bracket M8 x I.25 20 2.0 I4
Cowling and Stay M6 x 1.0 4 0.4 2.9
Compression Bar and Brake Caliper Bracket M8 x I.25 23 2.3 17
Front Fork Pinch Bolt M8 x I.25 20 2.0 14
Sprocket and Clutch Hub M8 x I.25 32 3.2 23
Brake Disc and Clutch Hub M8 x 1.25 20 2.0 14
Inner Tube and Steering Stem M8 x I.25 22 2.2 16
Frame and Rear Frame: Upper MlOx 1.25 64 6.4 46
Lower Ml2 x 1.25 88 8.8 64
-4-

GENERAL TORQUE SPECIFICATIONS Is4 P9l
GENERAL TORQUE SPECI FICA-
TIONS
This chart specifies torque for standard fasteners
with standard I.S.O. pitch threads. Torque
specifications for special components or assem-
blies are included in the applicable sections of
this book. To avoid warpage, tighten multi-
fastener assemblies in a crisscross fashion, in
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications
call for clean, dry threads. Components should
be at room temperature.
A: Distance across flats

6: O u t s i d e t h r e a d d i a m e t e r
DEFINITION OF UNITS
Unit Read Definition Measure

mm millimeter 10e3 meter Length
cm centimeter IO-* meter Length
kg kilogram lo3 gram Weight
N Newton 1 kg x m/set* Force
Nm Newton meter Nxm Torque
mskg Meter kilogram m x kg Torque
Pa Pascal N/m2 Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter
Volume or Capacity
cm3 Cubic centimeter
r/min Revolution per minute Engine Speed
-5-

DRIVE CHAIN SLACK ADJUSTMENT
PERIODIC INSPECTIONS
AND ADJUSTMENTS
CHASSIS
NOTE:
Before checking and/or adjusting the chain slack,
rotate the rear wheel several revolutions. Check
the chain slack several times to find the point
where the chain is the tightest. Check and/or
adjust the chain slack where the rear wheel is in
this “tight chain” position.
Too little of chain slack will overload the engine

and over vital parts; keep the slack within the
specified limits.
Securely support the motorcycle so there is

no danger of it falling over.
1. Place the motorcycle on a level place, and

hold it in an upright position.
2. Check:
?? Drive chain slack @
Out of specification + Adjust.
>
3. Adjust:
?? Drive chain slack
Adjustment steps:
?? Remove the cotter pin @ .
?? Loosen the axle nut @ .
?? Loosen both locknuts @ (adjuster) and
turn the adjuster @ clockwise or counter-

clockwise until the specified slack is
obtained.
- 6 -
.
I1NspI(
DRIVE CHAIN SLACK ADJUSTMENT ADJ m
Clockwise + Slack is increased.

Counterclockwise --, Slack is decreased.
NOTE:
Turn each adjuster exactly the same amount
to maintain correct axle alignment. (There are
marks on each side of swingarm; use them to
check for proper alignment.)
?? Tighten the locknut.
?? Tighten the axle nut to specification, while
pushing up or down on the chain to zero
slack.
107 Nm (10.7 m- kg, 77 ft. lb)
?? Install the cotter pin.
Always use a new cotter pin on the axle nut.
Do not loosen the axle nut after torque

tightening. If the axle nut groove is not
aligned with the cotter pin hole, align groove
rnrith the hole by tightening up on the axle
nut.
-7-

REAR WHEEL -1
CHASSIS
REAR WHEEL
@Collar
@ Oil seal
@ Bearing
@ Spacer
@ Clutch hub
@Collar
@ Cotter pin
@ Tension bar
140160R 18-64H
WEAR LIMIT:
1 .O mm (0.04 in)
RIM SIZE:
MT4.00 x 18
RIM RUNOUT LIMIT:

RADIAL:
2.0 mm (0.08 in)
LATERAL:
-8-

REAR WHEEL -1
REMOVAL
1. Place the motorcycle on a level place.
Securely support the motorcycle so there is no

danger of it falling over.
2. Elevate the rear wheel by placing a suitable

stand under the swingarm.
3. Remove:
?? Bolts (brake caliper) @
NOTE:
Do not depress the brake pedal while the caliper
is removed.
4. Loosen:
Locknut @
??
?? Adjuster @
5. Remove:
?? Cotter pin @I
*Axle nut @I
?? Washer @
6. Push the rear wheel forward and disconnect

the drive chain @ from the driven sprocket
0
7. Remove:
?? Rear wheel axle
?? Adjuster collars (left and right)

?? Rear wheel @
8. Remove:
?? Collar (left and right)
-9-

REAR WHEEL
INSPECTION
1. Inspect:
?? Tire
?? Rear wheel axle
?? Wheel
?? Wheel bearings
@Oil seals
Refer to the “FRONT WHEEL - INSPEC-
TION”.
2. Measure:
?? Wheel runout
Refer to the “FRONT WHEEL - INSPEC- .

TION”.
3. Check:
?? Wheel balance
Refer to the “FRONT WHEEL - INSPEC-

TION”.
INSTALLATION
Reverse the “Removal” procedure.
Note the following points.
1. Lubricate:
?? Rear wheel axle
?? Bearings
*Oil seals
?? Spacer
?? Collar
Lithium soap base grease
2. Adjust:
Drive chain slack:

10 - 20 mm (0.4 - 0.8 in)
Refer to the “DRIVE CHAIN SLACK

ADJUSTMENT”.
3. Tighten:
?? Nut (rear wheel axle)
?? Bolts (brake caliper)

REAR WHEEL lctf=l &x31
?? Do not loosen the axle nut after torque tighten-

ing.
?? If the axle nut groove is not aligned with the
wheel shaft cotter pin hole, align groove with
the hole by tightening up on the axle nut.
4. Install:
aCotter pin
?? Always use a new cotter pin on the axle nut.

?? Make sure that the brake hose is routed prop-
erly.
@Brake hose
@ Brake hose guide
STATIC WHEEL BALANCE ADJUSTMENT
NOTE:
?? After replacing the tire and/or rim, wheel
balance should be adjusted.
?? Adjust the wheel balance with brake disc
and wheel hub installed.
1. Adjust:
?? Wheel balance
Refer to the “FRONT WHEEL -STATIC
WHEEL BALANCE ADJUSTMENT”
section.
-ll-

pqzq
FRONT AND REAR BRAKE
@ Master cylinder cap @ Brake caliper ? The arrow mark @ on the pad spring must pointing
@ Diaphragm @I Pad spring the disc rotating direction.
@ Master cylinder kit Q-j? Piston
@ Master cylinder @ Piston seal
@ Brake hose @ Dust seal
@ Union bolt @Brake pad
@ Copper washer @ Brake disc
@ Joint
1 BRAKE FLUID TYPE:

A DOT#4 2 Nm (0.2 rn. kg, 1.4 ftslb)
If DOT #4 is not available,
I-
1 PAD SPRING
SYL I ---‘---- -
135 (3.5 m . kg, 25 ft. lb) 1// ,
20 Nm (2.0 ma kg,
rd lJSF NEW ONE 1 \ yr;\r ONA

26
k
FRONT AND REAR BRAKE l-s1 @bibi
@ Reservoir tank cap @ Union bolt

@ Bush 0 Copper washer
@Diaphragm @Brake caliper
@ Reservoir tank @Piston
@ Reservoir hose @Piston seal
@ Master cylinder @ Dust seal
@ Master cylinder kit @I Brake pad
@ Brake hose @ Pad shim
@ Brake pedal @I Pad spring
@Brake disc
>/26Nm (2.6m=kg, 19ft*Ib)I
~20NmI2.0m.kn 14ft.lhl)
- 13-

FRONT AND REAR BRAKE pi$q
Disc brake components rarely require disassem-

bly. DO NOT:
?? Disassembly components unless absolutely nec-
essary.
?? Use solvents on internal brake component.
?? Use contaminated brake fluid for cleaning.
Use only clean brake fluid.

?? AIIOW brake fluid to come in contact with the
eyes otherwise eye injury may occur.
?? Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may occur.

?? Disconnect any hydraulic connection other-
wise the entire system must be disassembled,

drained, cleaned, and then properly filled and
bled after reassembly.
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.

Front brake
1. Remove:
??Cover @

FRONT AND REAR BRAKE -1
3. Remove:
?? Brake pads @
NOTE:
?? Replace the pad spring if the pad replacement
is required.
?? Replace the pads as a set if either is found to
be worn to the wear limit.
0.5 mm (0.02 in)
4. Install:
?? Brake pads @
?? Pad spring @
Installation steps:
@Connect a suitable hose @ tightly to the
caliper bleed screw. Then, place the other
end of this hose into an open container.
?? Loosen the caliper bleed screw and push the
piston into the caliper by your finger.
*Tighten the caliper bleed screw.
Caliper bleed screw:

6 Nm (0.6 m- kg, 4.3 ft. lb)
*Install the brake pad (new) and pad spring

(new).
NOTE:
The arrow mark @ on the pad spring must
point in the disc rotating direction.
-15-

6. Inspect:
?? Brake fluid level
Refer to the “BRAKE FLUID INSPEC-

TION” section in the CHAPTER 3.
@ “LOWER” level line
7. Check:
?? Brake lever operation
A softy or spongy filling + Bleed brake

system.
Refer to the “Al R BLEEDING” section in
the CHAPTER 3.
Rear brake
1. Remove:
?? Seat
2. Remove:
3. Remove:
e Retaining bolts @
-16-

FRONT AND REAR BRAKE b-l &I
4. Remove:
?? Brake pads (with shims) @
?? Pad spring @
NOTE :
?? Replace the pad spring if the pad replacement
is required.
?? Replace the pads as a set if either is found to

?? Replace the pad shim if the pad replacement is
required.
0.5 mm (0.02 in)
5. Install:
@Pad shims @
?? Pad spring @
?? Brake pads (with shims) @
Installation steps:
@Connect a suitable hose @ tightly to the
caliper bleed screw. Then, place the other
end of this hose into an open container.
?? Loosen the caliper bleed screw and push the
piston into the caliper by your finger.

*Tighten the caliper bleed screw.
Caliper bleed screw:

6 Nm (0.6 m - kg, 4.3 ft - lb)
@Install the brake pads (new), pad spring

(new) and pad shims (new).
NOTE:
Install pad shims @ and pad spring @ on
caliper as shown in the disc rotating direction.

6. Install:
?? Retaining bolts @
Retaining bolts:
10 Nm (1.0 ma kg, 7.2 ft. lb)
7. Install:
Bolts (brake caliper):

35 Nm (3.5 rn- kg, 25 ft. lb)
8. Inspect:

@ “LOWER” level line
9. Check:
?? Brake pedal operation
A softy or spongy filling + Bleed brake

system.
Refer to the “AIR BLEEDING” section in
the CHAPTER 3.
10. Install:
?? Seat
- 18-

FRONTANDREARBRAKE ICHASl c&x31
CALIPER DISASSEMBLY
NOTE:
Before disassembling the front or rear brake
master cylinders, drain the brake hose, master
cylinder, brake caliper and reservoir tank of
their brake fluid.

Front brake
1. Remove:
0 Cover
0 Reflector
0 Retaining clips
?? Retaining pins
?? Pad spring
?? Brake pads
Refer to the “BRAKE PAD REPLACE-

MENT” section.
2. Remove:
Union bolt @
??
?? Copper washers @
?? Brake hose @
Place the open hose end into a container

and pump the old fluid out carefully.
3. Remove:
?? Caliper body
Do not loosen the bridge bolts @ .
- 19-

4. Remove:
?? Pistons 0
?? Dust seals @
?? Piston seals @I
Remove steps:
*Blow compressed air into the tube joint
opening to force out the piston from the
caliper body.
?? Never try to pry out the piston.

?? Cover the piston with a rag. Use care so that
piston does not cause injury as it is expelled
from the cylinder.
Rear brake
1. Remove:
?? Bolts (brake caliper)
?? Retaining bolts
?? Brake pads (with Sims)
?? Brake spring
Refer to “BRAKE PAD REPLACEMENT”

section.
2. Remove:
?? Union bolt @
?? Copper washers @
?? Brake hose @

3. Remove:
?? Pistons 0
?? Dust seals @
0 Piston seals @
Do not loosen the bridge bolts @ .
- 20 -

FRONT AND REAR BRAKE pi&E&l
Remove steps:
?? Blow compressed air into the tube joint

caliper body.


from the cylinder.
MASTER CYLINDER DISASSEMBLY
NOTE:
master cylinders, drain the brake hose, master
cylinder, brake caliper and reservoir tank of
their brake fluid.

Front brake
1. Remove:
?? Brake lever @I
?? Brake switch @
2. Remove:
?? Union bolt @
?? Copper washer @
?? Brake hose @


pqiq
3. Remove:
?? Master cylinder @
4. Remove:
?? Cap (master cylinder) 6)
?? Diaphragm @
. Dust boot @
?? Circlip 0
?? Master cylinder kit @
Rear brake
1. Remove:
0 Seat
?? Side cover (right)
2. Remove:
?? Cotter pin @
?? Washer @
ePin @I
3. Disconnect:
?? Reservoir hose @

4. Remove:
?? Union bolt @
?? Copper washers

5. Remove:
6. Remove:
. Dust boot @
0 Circlip @
?? Push rod @
- 22 -
I I 1
FRONT AND REAR BRAKE ICHASl &I

7. Remove:
?? Reservoir tank @
(from flame)
?? Cap (reservoir tank) @
?? Holder (diaphragm) @
?? Diaphragm @
INSPECTION AND REPAIR
All internal parts should be cleaned in new brake

fluid only. Do not use solvents will cause seals
to swell and distort.
“a. L‘ 1. Inspect:
@Caliper pistons (iJ
Scratches/Rust/Wear + Replace.
I @Caliper cylinders @
Wear/Scratches + Replace.
?? Front
?? Rear
Replace the piston seal and dust seal whenever

a caliper is disassembled.
2. Inspect:
?? Caliper body @
Cracks/Damage + Replace.
?? 0il delivery passage (caliper body)
3* Blow out with compressed air.
$(I* Jsil
)
m Front
??
Rear
- 23 -

pii&q
3. Inspect :
Wear/Scratches -+ Replace.
?? Master cylinder body @
*Oil delivery passage (master cylinder body)
Blow out with compressed air.
@I F r o n t
Et1 Rear
4. Inspect:
Scratches/Wear/Damage --f Replace.
?? Front
m Rear
5. Inspect:
?? Diaphragm (front) @
?? Diaphragm (rear) @
Wear/Damage -+ Replace.
?? Reservoir tank @
Cracks/Damage -+ Replace.
[&j F r o n t
@] R e a r
-- 24 -

6. Inspect:
?? Brake hoses @
Cracks/Wear/Damage -+ Replace.
?? Front
[Bl R e a r
7. Measure:
?? Brake pads (thickness) @
Out of specification + Replace.
Wear limit:
0.5 mm (0.02 in)
NOTE:
?? Replace the pad spring as a set if pad replace-
ment is required.
?? Replace the pads as a set if either if found to
- 25 -

ASSEMBLY
*All internal parts should be cleaned in new

brake fluid only.
?? Internal parts should be lubricated with brake
fluid when installed.

?? Replace the piston seal and dust seal whenever
a caliper is disassembled.
?? Securely support the motorcycle so there is
Brake fluid:
DOT #4
If DOT #4 is not available.
#3 can be used.
Front brake
1. Install:
?? Piston seals 0
?? Dust seals @
?? Pistons @
Always use new piston seal and dust seal.
2. Install:
?? Brake pads
?? Pad spring
0 Retaining pins
0 Retaining trips
?? Cover
MENT” section.
3. Install:
?? Brake caliper
?? Reflector

35 Nm (3.5 m - kg, 25 ft. lb)
- 26 -

FRONT AND REAR BRAKE bHAsi @@d
4. Install:
?? Copper washers @
?? Brake hose @
aUnion bolt @
(onto brake caliper)
Union bolt:
26 Nm (2.6 m - kg, 19 ft. lb)
When installing the brake hose to the caliper

0, lightly touch the brake pipe with the projec-
tion @ on brake caliper.
?? Proper hose routing is essential to insure safe

motorcycle operation. Refer to “CABLE
ROUTING”.
?? Always use new copper washers.
5. Install:
0 Circlip @
.Dust boot @
6. Install:
NOTE :
Tighten first the upper bolt, then the lower bolt.
Bolts (master cylinder bracket):

9 Nm (0.9 m - kg, 6.5 ft. lb)
-27 -

7. Install:
?? Brake hose @
?? Copper washers @
?? Union bolts @
26 Nm (2.6 m - kg, 19 ft- lb)
*Proper hose routing is essential to insure safe

motorcycle operation. Refer to the “CABLE
ROUTING”.
?? Always use new copper washers.
8. Install:
?? Brake switch @
*Spring @
*Brake lever @
NOTE:
Apply lithium soap base grease to pivot shaft of
brake lever.
9. Fill:
?? Brake fluid
Recommended brake fluid:

DOT #4
#3 can be used.
Brake fluid may erode painted surfaces or

plastic parts. Always clean up spilled fluid
immediately.
?? Use only the designated quality brake fluid:

otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
?? Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemical

reaction and lead to poor performance.
?? Be careful that water does not enter the master
cylinder when refilling. Water will significantly

lower the boiling point of the fluid and may
result in vapor lock.
-28 -

10. Install:
?? Diaphragm @
?? Master cylinder cap @
Screws (master cylinder cap):

2 Nm (0.2 m - kg, 1.4 ft. lb)
11. Air bleed:

@Brake system
Refer to the “AIR BLEEDING” section
in the CHAPTER 3.
12. Inspect:
Fluid lever is under “LOWER” level line @

+ Replenish.
Rear brake
1. Install:
0 Piston seals (iJ
@Dust seals @
aPistons @
2. Install:
*Pad spring @
*Brake pads (with shims) @
?? Retaining bolts
Retaining bolts:
10 Nm (1.0 m- kg, 13 ft. lb)

MENT” section.
29 -

FRONT AND REAR BRAKE pi$q
3. Install:
?? Brake caliper 0

35 Nm (3.5 m - kg, 25 ft. lb)
4. Install:
?? Push rod @
0 Circlip @
.Dust boot @
5. Install:
?? Master cylinder assembly @
\
Bolts (master cylinder assembly):
35 Nm (3.5 m - kg, 25 ft. lb)
6. Install:
OPin 0
@Plain washer @
?? Cotter pin @
Always use new cotter pin.
7. Install:
?? Reservoir tank

FRONT AND REAR BRAKE lct-~ebbi
8. Install:
?? Brake hose
?? Copper washers
?? Union bolts
?? Reservoir hose
I Union bolts:
26 Nm (2.6 rn- kg, 19 ft. lb) I
When installing the brake hose, lightly touch

the brake pipe @ with the projections @ on
the caliper and master cylinder.
?? Master cylinder
[Bl Brake caliper
aProper hose routing is essential to insure safe

motorcycle operation, Refer to the “CABLE
ROUTING”.
@Always use new copper washers.
@ Brake hose
@ Brake hose guide
9. Fill:
*Brake fluid
Brake fluid may erode painted surfaces or plastic

parts. Always clean up spilled fluid immediately.
-3l-

FRONT AND REAR BRAKE [iiiqq

mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
?? Be careful that water does not enter the
master cylinder when refilling. Water will

significantly lower the boiling point of the
fluid and may result in vapor lock.
IO. Install:
?? Diaphragm @
??Bush @
?? Reservoir tank cap @
11. Air bleed:

?? Brake system
Refer to the “AIR BLEEDING” ??????? ? in
the CHAPTER 3.
12. Inspect:
Fluid level is under “LOWER” level line @

+ Replenish.
13. Adjust:
?? Rear brake pedal height @
Pedal height:
42 mm (1.7 in)
Below top of footrest.
Refer to “REAR BRAKE ADJUSTMENT”

section in the CHAPTER 3.
14. Install:
?? Side cover (right)
0 Seat
- 32 -
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . l-l
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . ....... l-2

PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . ....... l-2
ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . ....... l-2
GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . ....... l-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . ....... l-3
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . ....... l-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... l-3
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-4

FOR TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-5
FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-B
FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-9
CHAPTER 2.
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ENGINE................................................2- 4
CHASSIS...............................................2-11
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
GENERAL TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2-16
DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . 2-17
LUBRICATION DIAGRAM. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-20
COOLANT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
................................. . . . . . . . . . . . . 2-21
CABLE ROUTING

CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 3-1
MAINTENANCE INTERVALS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-l

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM . . . . . . . . .3-l
GENERAL MAINTENANCE/LUBRICATION . . . . . . . . . . . . . . . . . . . . . .3-2
COWLING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .3-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
EXUP CABLE ADJUSTMENT (For California only) . . . . . . . . . . . . . . . . 3-7
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
THROTTLE CABLE FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . 3-18
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . 3-21
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CLUTCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CARBURETOR JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CRANKCASE VENTILATION HOSE INSPECTION . . . . . . . . . . . . . . . . 3-28
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHASSIS ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
REAR BRAKE LIGHT SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . 3-33
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
AIR BLEEDlNG............................................3-3 4
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 3-40
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
TAIL/BRAKE BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-l

UPPER COWLING AND TOP COVER. . . . . . . . . . . . . . . . . . . . . . . . . . .4-l
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-l
ENGINEOIL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.........4- 1
COOLANT.................................................4- 1
AIR FILTER CASE AND CARBURETOR., . . . . . . . . . . . . . . . . . . . . . . .4-l
RADIATOR................................................4- 2
MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
CLUTCH CABLE AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
LEADS....................................................4- 4
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
CLUTCH..................................................4-13
A.C. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
OIL PUMP AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
OIL PAN AND OIL STRAINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
TRANSMISSION, SHIFTER AND SHIFT CAM. . . . . . . . . . . . . . . . . . . . 4-19
............................................. 4-20
CRANKSHAFT
VALVE PAD AND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
INNER ROTOR (OIL PUMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . 4-24
VALVE...................................................4-2 5
VALVE GUIDE . . . . . . . . I:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
VALVE SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
VALVE LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
CAMSHAFT, CAM CHAIN AND CAM SPROCKET . . . . . . . . . . . . . . . . .4-31

PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
CRANKSHAFT AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . 4-37
OlLPUMP.................................................4-4 1
PRlMARYDRlVE..........................................4-4 2
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
CLUTCH..................................................4-4 4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
RELIEF VALVE AND PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
BEARING AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
ENGINE ASSEMBLY AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .4-49

INNER ROTOR (OIL PUMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
CONNECTING ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
VALVE PAD AND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
TRANSMISSION, SHIFTER AND SHIFT CAM . . . . . . . . . . . . . . . . . . . .4-56
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
OIL PAN AND OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
OIL PUMP AND SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60
A.C. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61
CLUTCH..................................................4-6 3
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65
PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67
CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70
CAM CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75
REMOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

CHAPTER 5.
COOLING SYSTEM
RADlATOR...................................................5- 1
REMOVAL.................................................5- 2
INSPECTION...............................................5- 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
WATER PUMP AND THERMOSTATIC VALVE. . . . . . . . . . . . . . . . . . . . . . . 5-6

REMOVAL.................................................5- 7
lNSPECTlON...............................................5- 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
CHAPTER 6.
CARBURETOR
............................................... 6-l
CARBURETOR
SECTIONVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
............................................ 6-5
DISASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-B
ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
........................................... 6-9 ,: i;
INSTALLATION
............................................. 6-10
ADJUSTMENT
CHAPTER 7.
CHASSIS
.............................................. 7-l
FRONT WHEEL.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-B
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-B
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

FRONT AND REAR BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
BRAKE PAD REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

REMOVAL................................................7-2 9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
lNSPECTlON..............................................7-3 1
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
STEERING HEAD AND HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

REMOVAL................................................7-3 8
lNSPECTlON..............................................7-4 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . . . . 7-47

HANDLING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
DISPOSAL NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
REMOVAL................................................7-4 9
lNSPECTlON..............................................7-5 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
DRIVE CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

REMOVAL................................................7-5 6
INSPECTION AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
INSTALL’ATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

CHAPTER 8.
ELECTRICAL
FZR400U/SUC CIRCUIT DIAGRAM ............................ 8-1
ELECTRICAL COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING OF SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

SWITCH CONNECTION AS SHOWN IN MANUAL . . . . . . . . . . . . . . . . . .8-5
CHECKING SWITCH FOR TERMINAL CONNECTION . . . . . . . . . . . . . .8-5
CHECKING OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

KINDS OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
CHECKING BULB CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-l 1

Cl RCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION . . . . . . . . . . . 8-13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-13
ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

CIRCUITDIAGRAM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-3 3
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
SIGNALSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
SIGNAL SYSTEM CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69

Cl RCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
FUELSYSTEM................................................8.7 5
....................................... .8-75
CIRCUIT DIAGRAM
............................ 8.77
FUEL PUMP CIRCUIT OPERATION
FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-82

(For California only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85
METER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89

REMOVAL................................................8-9 0
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE.. . . . . . . . . . . . . . . . . 9-4
FAULTY GEAR SHIFTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
OVERHEATING OR OVER-COOLING.. . . . . . . . . . I.. . . . . . . . . . . . . . . . . 9-6
FAULTY BRAKE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _. . . . 9-7
FRONT FORK OIL LEAKAGE/MALFUNCTION.. . . . . . . . . . . . . . . . . . . . . 9-7
INSTABLE HANDLING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FAULTY SIGNALS AND LIGHTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
FAULTY EXUP (For California only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-l 0

MOTORCYCLE IDENTIFICATION INFO 6%
I ” ‘ ”
GENERAL
tNFORMATtON
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number @ is stemped
into the right side of the steering head.
FZR400U (Except for California):
NOTE:
The vehicle identification number is used to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your state.
ENGINE SERIAL NUMBER

The engine serial number @ is stamped into the
right side of the engine.
FZR400U (Except for California):
NOTE:
*The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
?? Designs and specifications are subject to
change without notice.
FZR4OOU FZR400SUC
l-1

IMPORTANT INFORMATIONp-piq
INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.

Refer to “SPECIAL TOOL”.
3. When disassembling the machine, keep

mated parts together. This includes gears,
cylinders, pistons, and other mated parts
that have been “mated” through normal
wear. Mated parts must be reused as an
assembly or replaced.
4. During the machines disassembly, clean all

parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all re-
placements. Use oil and/or grease recom-
mended by Yamaha for assembly and adjust-
ment. Other brands may be similar in func-
tion and appearance, but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals, and O-rings should be re-
placed when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil
seal lips.
1-2

IMPORTANT INFORMATION INFO 8%
lGEN
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates @ and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been pro-
perly tightened.
300 000
BEARINGS AND OIL SEALS

1. Install the bearing(s) @ and oil seal(s) @
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side exposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seal lip(s). Oil the bearings libe-
300 003
rally when installing.
@ Oil seal
Do not use compressed air to spin the bearings

dry. This causes damage to the bearing surfaces.
@ Bearing
CIRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted cir-
clips. When installing a circlip @ , make sure
that the sharp edged corner @ is positioned
opposite to the thrust @ it receives. See the
sectional view.
@ Shaft
l-3

SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or impro-
vised techniques.
FOR TUNE UP
1. Inductive Tachometer
P/N W-08036
This tool is needed for detecting engine rpm.
2. Inductive Timing Light

P/N Y U-08037
This tool is necessary for checking ignition

timing.
3. Compression Gauge
P/N YU-33223
This gauge is used to measure the engine com-

pression.
4. Fuel Level Gauge

P/N YU-01312
This gauge is used to measure the fuel level in

the float chamber.
1-4

SPECIAL TOOLS INFO df@
lGENl
5. Vacuum Gauge
P/N YU-08030
This gauge is needed for carburetor synchroniza-

tion.
FOR ENGINE SERVICE

1. Cam Chain Cutter
P/N Y M-01 112
This tool is used when cutting the cam chain.
2. Piston Pin Puller

P/N YU-01304
This tool is used to remove the piston pin.
3. Universal Clutch Holder

P/N YM-91042
This tool is used to hold the clutch when re-

moving or installing the clutch boss locknut.
4. Rotor Puller
P/N YM-01080
This tool is used to remove the rotor.
1-5

SPECIAL TOOLS INFO d!@
JGEN/
5. Universal Rotor Holder
P/N YU-01235
This tool is used when loosening or tightening the

A.C. magneto securing bolt.
6. Heavy Duty Puller

P/N Y U-33270
This tool is used to remove the starter clutch.
7. Camshaft Wrench
P/N YM-04115
This tool is used to turn the camshaft.
8. Valve Spring Compressor @

P/N YM-04019
Attachment @
P/N YM-04114
This tool is needed to remove and install the

valve assemblies.
9. Valve Guide l?emover (4.5 mm)

P/N YM-04116
This tool is used to remove the valve guides.
I-6

SPECIAL TOOLS ppq
INFO
IO. Valve Guide Installer

P/N YM-041 I7
This tool is needed to install the valve guides

properly.
1 I. Valve Guide Reamer (4.5 mm)

P/N YM-041 I8
This tool is used to rebore the new valve guide.
12. Valve Seat Cutter

P/N YM-91043
This tool is needed to resurface the valve seat.
13. Plastigage@ Set “Green”

P/N YU-33210
This gauge is needed to measure the clearance
for the connecting rod bearing and the crank
shaft bearing.
14. Quick Gasket@

P/N ACC-I 1001-05-01
This sealant (Bond) is used for crankcase mating

surfaces, etc.
1-7

SPECIAL TOOLS INFO d@@
lz7l-l
15. Piston Base
P/N Y M-01 067
Use 4 of these to hold the piston during cylinder

installation.
16. Radiator Cap Tester

P/N Y U-24460-01
Adaptor
P/N Y U-33984
This tester is needed for checking the cooling

system.
FOR CHASSIS SERVICE

I. T-Handle
P/N YM-01326 - @
Front Fork Cylinder Holder
P/N YM-01300-1 - @
This tool is used to loosen and tighten the front

fork damper rod holding bolt.
2. Front Fork Seal Driver (weight)

P/N YM-33963 - @
Adapter (38 mm)
P/N YM-01372 - @
These tools are used when installing the fork

seat.
3. Ring Nut Wrench

P/N Y U-33975
This tool is used to loosen and tighten the steer-

ing ring nut.
1-8
SPECIAL TOOLS p+ij
INFO
FOR ELECTRICAL COMPONENTS
1. Dynamic Coil Tester
P/N Y M-34487
This tester is necessary for checking the ignition

system components.
2. Pocket Tester
P/N Y U-031 12
This instrument is invaluable for checking the

electrical system.
l-9

GENERAL SPECIFICATIONS (SPECII
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model FZf?400U/FZR400SUC
Model Code Number: 3BF (FZR400U)
3 F H (FZR400SUC)
Vehicle Identification Number: JYA3FHCO * JAOOOlOl
JYA3BFEO * JAOOOlOl
Engine Starting Number: 3BF-000101 (FZR400U)
3FH-000101 (FZR400SUC)
Dimensions:
Overall Length 2,070 mm (81.5 in)
Overall Width 690 mm (27.2 in)
Overall Height 1,125 mm (44.3 in)
Seat Height 785 mm (30.9 in)
Wheelbase 1,400 mm (55.1 in)
Minimum Ground Clearance 135 mm ( 5.31 in)
Basic Weight:
With Oil and Full Fuel Tank 186 kg (410 lb) (FZR400U)
189 kg (417 lb) (FZR400SUC)
Vlinimum Turning Radius: 3,100 mm (122 in)
Engine:
Engine Type Liquide cooled 4stroke, gasoline, DOHC
Cylinder Arrangement 4-cylinder parallel
Displacement 399 cm3 (24.3 cu.in)
Bore x Stroke 56.0 x 40.5 mm (2.2047 x 1.5945 in)
Compression Ratio 11.5 : 1
Compression Pressure 932 kPa (9.5 kg/cm’, 135 psi)
Starting System Electric starter
Lubrication System: Wet sump
Engine Oil Type or Grade:
30 40 50 60°F
Yamalube 4cycle oil or
* - -
SAE 2OW40 type SE motor oil
- - w SAE lOW30 type SE motor oil
0 5 10 15°C
Engine Oil Capacity:

Engine Oil:
Periodic Oil Change: 2.2 L (1.9 Imp qt, 2.33 US qt)
With Oil Filter Replacement 2.5 L (2.2 Imp qt, 2.64 US qt)
Total Amount 3.0 L (2.6 Imp qt, 3.17 US qt)
Coolant Total Amount:
(Including All Routes) 1.9 L (1.7 Imp qt, 2.0 US qt)
4ir Filter: Dry type element
2-l

GENERAL SPECIFICATIONS (,,,,I1
Model FZ R400U/FZR400SUC
=uel:
Type Unleaded fuel recommended
Tank capacity 18.0 L (3.94 Imp gal, 4.8 US gal)
Reserve Amoun 3.0 L (0.66 Imp gal, 0.79 US gal)
zarburetor:
Type x Quantity BDS32 x 4
Manufacturer MIKUNI
spark Plug:
Type (Manufacture) CR8E (NGK), U24ESR-N (N.D.)
Gap 0.7 - 0.8 mm (0.028 - 0.032 in)
Jutch Type: Wet, multiple-disc
Transmission:
Primary Reduction System Spur gear
Primary Reduction Ratio 89/41 (2.170)
Secondary Reduction System Chain drive
Secondary Reduction Ratio 55/19 (2.894)
Transmission Type Constant-mesh, 6-speed
Operation Left foot operation
Gear Ratio 1 st 43/l 3 (3.307)
2nd 40/18 (2.222)
3rd 36/21 (1.714)
4th 33123 (1.434)
5th 28/22 ( 1.272 1
6th 27/23 (1.173)
zhassis:
Frame Type Double cradle
Caster Angle 24”
Trail 89 mm (3.5 in)
Tire Front Rear
Type Tubeless Tubeless
Size 110/70R17-53H 140/60 R 18-64H
Manufacture (Type) BRIDGESTONE BRIDGESTONE
(CY ROX-03) (CY ROX-04)
DUNLOP DUNLOP
(K455F) (K455)
vlaximum Load * 156 kg (344 lb) (Except for California)
153 kg (337 lb) (For California)
Tire Pressure (Cold tire): Front Rear
200kPa 230kPa
Up to 90 kg (198 lb) load* (2.0 kg/cm2 ,28 psi) (2,3 kg/cm2, 32 psi)
200kPa 250 kPa
90 kg (198 lb) - Maximum load* (2.5 kg/cm’, 36 psi)
(2.0 kg/cm’ , 28 psi)
200 kPa 250 kPa
High speed riding (2.5 kg/cm’, 36 psi)
(2.0 kg/cm2, 28 psi)
*Load is total weight of cargo, rider, passenger, and accessories.
2-2

GENERAL SPECIFICATIONS ISPEC\p(y\
Model FZR400U/FZR400SUC
Brake:
Front Brake Type Dual disc brake
Operation Right hand operation
Rear Brake Type Single disc brake
Operation Right foot operation
Suspension:
Front Suspension Telescopic fork
Rear Suspension Swingarm (New monocross)
Shock Absorber:
Front Shock Absorber Coil spring/Oil damper
Rear Shock Absorber Coil gas spring/Oil damper
Wheel Travel:
Front Wheel Travel 130 mm (5.12 in)
Rear Wehel Travel 130 mm (5.12 in)
Electrical:
Ignition System T.C.I. (Digital ignition)
Generator System A.C. magneto generator
Battery Type or Model GM 12AZ-3A-2
Battery Capacity 12V 12AH
Headlight type: Quartz bulb (Halogen)
Bulb Wattage x Quantity:
Headlight 35w/35w x 2
Tail/Brake Light 8W/27W x 1
Rear Flasher Light 27Wx2
Front Position Light/Front Flasher Light 27W/8W x 2
License Light 3.8W x 2
Meter Light 1.7w x 5
Auxiliary Light 3.4w x 2
Indicator Light:
Wattage x Quantity “NEUTRAL” 3.4w x 1
“HIGH BEAM” 3.4w x 1
“TURN” 3.4w x 1
“01 L LEVEL” 3.4w x 1
t
“I,
Y
2-3

MAINTENANCE SPECIFICATIONS (,,,,I1
Engine
Cylinder Head:
Warp Limit* 0.03 mm (0.0012 in)
, *Lines indicate straightedge measurement
Cylinder:
Bore Size 56.000 - 56.005 mm (2.2047 - 2.2049 ir
Drive Method Chain drive (Center)

Cam Cap Inside Dia. 23.000 - 23.021 mm (0.9055 - 0.9063 ir
Camshaft Outside Dia. 22.967 - 22.980 mm (0.9042 - 0.9047 ir

Shaft-to-Cap Clearance 0.020 - 0.054 mm (0.0008 - 0.0021 in)
< Limit > 0.08 mm (0.0031 in)
Cam Dimensions: Intake 32.55 - 32.65 mm (1.2815 - 1.2854 in)
32.51 mm (1.2799 in)
25.045 - 25.145 mm (0.986 - 0.990 in)
25.005 mm (0.9844 in)
32.25 - 32.35 mm (1.2697 - 1.2736 in)

32.21 mm (1.2681 in)
25.0 - 25.1 mm (0.9843 - 0.9882 in)
24.96 mm (0.9827 in)
zamshaft Runout Limit 0.03 mm (0.0012 in)
Cam Chain Type/No. of Links BFO4MA/l12 Links

Cam Chain Adjustment Method
Jalvt, Valve Seat, Valve Guide:
Valve Clearance (Cold):
Valve Dimensions:
Head Dia. Face Width Seat Width Margin Thickne
2-4

c “A” Head Dia.

Model
I
EX.
N .
I FZR400U/FZR40OSlJC
21.9 - 22.1 mm (0.8622 - 0.8701 in)
18.9 - 19.1 mm (0.7441 - 0.7520 in)
“6” Face Width IN. 1.6 - 2.4 mm (0.0630 - 0.0945 in)
EX. 1.6 - 2.4 mm (0.0630 - 0.0945 in)
“C” Seat Width IN. 0.9 - 1 .l mm (0.0354 - 0.0433 in)
EX. 0.9 - 1 .l mm (0.0354 - 0.0433 in)
< Limit > IN. 1.6 mm (0.063 in)
EX. 1.6 mm (0.063 in)
“D” Margin Thickness IN. 0.6 - 0.8 mm (0.0236 - 0.0315 in)
EX. 0.6 - 0.8 mm (0.0236 - 0.0315 in)
< Limit > IN. 0.4 mm (0.0157 in)
EX. 0.4 mm (0.0157 in)
Stem Outside Diameter IN. 4.475 - 4.490 mm (0.1762 - 0.1768 in)
EX. 4.460 - 4.475 mm (0.1756 - 0.1762 in)
< Limit > IN. 4.45 mm (0.175 in)
EX. 4.435 mm (0.175 in)
Guide Inside Diameter IN. 4.500 - 4.512 mm (0.1772 - 0.1776 in)
EX. 4.500 - 4.512 mm (0.1772 - 0.1776 in)
< Limit > IN. 4.542 mm (0.179 in)
EX. 4.542 mm (0.179 in)
Stem-to-Guide Clearance IN. 0.010 - 0.037 mm (0.0004 - 0.0015 in)
EX. 0.025 - 0.052 mm (0.001 - 0.002 in)
< Limit > IN. 0.08 mm (0.0031 in)
EX. 0.1 mm (0.0039 in)
Stem Runout Limit 0.02 mm (0.0008 in)
Valve Seat Width IN. 0.9 -1 .l mm (0.0354 - 0.0433 in)

EX. 0.9 -1 .l mm (0.0354 - 0.0433 in)
< Limit > IN. 1.6 mm (0.063 in)
EX. 1.6 mm (0.063 in)
i‘alve Spring:
Free Length IN. 41.94 mm (1.65 in)
EX. 41.94 mm (1.65 in)
Installed Length (Valve Closed) IN. 37.5 mm (1.48 in)
EX. 37.5 mm (1.48 in)
Compressed Pressure IN. 14.2 - 16.4 kg (31.3 - 36.2 lb)
(Valve closed) EX. 14.2 - 16.4 kg (31.3 - 36.2 lb)
Tilt Limit IN. 2.5”/1.8 mm (0.0709 in)
EX. 2.5”/1.8 mm (0.0709 in)
I+-
diiiJiL
/%
Direction of Winding (Top view) IN.

EX.

MAINTENANCE SPECIFICATIONS piqjqJ
Won:
Piston Size “D” 55.945 - 55.960 mm (2.2026 - 2.2031 in)
Measuring Point “H” 5 mm (0.197 in)
(From bottom line of piston skirt)
- - - - - - - -
H
ED+
D
Piston-to-Cylinder Clearance 0.04 - 0.06 mm (0.0016 - 0.0024 in)
< Limit> < 0.15 mm (0.006 in) >
Oversize: 2nd 56.5 mm (2.22 in)
4th 57.0 mm (2.24 in)
>iston Ring:
Sectional Sketch Top Ring Barrel
T B = 0.8 mm (0.0315 in)
B T = 2.1 mm (0.0827 in)
&I
2nd Ring Taper
B = 0.8 mm (0.0315 in)
T = 2.1 mm (0.0827 in)
LAB
ek,
Oil Ring Expander
B = 2.0 mm (0.0787 in)
T = 2.2 mm (0.0866 in)
IL
&
End Gap (Installed): ’ Top Ring 0.15 - 0.30 mm (0.0059 - 0.0118 in)
2nd Ring 1 0.15 - 0.30 mm (0.0059- 0.0118 in)
Oil Ring 0.2 - 0.8 mm (0.0079 - 0.0315 in)
Side Clearance: Top Ring 0.03 - 0.07 mm (0.0012 - 0.0028 in)
< Limit > 0.10 mm (0.004 in)
2nd Ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
< Limit > 0.10 mm (0.004 in)
Oil Ring -
zonnecting Rod:
Connecting Rod Oil Clearance 0.043 - 0.066 mm (0.0017 - 0.0026 in)
Bearing Size No. Color Code 1. Blue 2. Black 3. Blown 4. Green
zrankshaft:
Runout Limit “A” 0.03 mm (0.0012 in)

Big End Side Clearance “B” 0.160 - 0.262 mm (0.0063 - 0.0103 in)
2-6

MAINTENANCE SPECIFICATIONS piqjq
Main Journal Oil Clearance 0.025 - 0.043 mm (0.0010 - 0.0017 in)
Bearing Size No. Color Code 1. Blue 2. Black 3. Brown 4. Green
5. Yellow
Clutch:
Friction Plate Thickness x Quantity 2.9 - 3.1 mm (0.114 - 0.122 in) x 8
Wear Limit 2.8 mm (0.11 in)
Clutch Plate Thickness x Quantity 1.8 - 2.2 mm (0.072 - 0.085 in) x 7
Warp Limit 0.1 mm (0.04 in)
Clutch Spring Free Length x Quantity 0.1 mm (0.004 in)
Clutch Spring Minimum Length 29.0 mm (1.14 in)
Clutch Housing Thrust Clearance 0.02 - 0.10 mm (0.0008 - 0.0039 in)
Clutch Release Method Inner push, screw - push
Push Rod Bending Limit 0.5 mm (0.020 in)
Transmission:
Main Axle Deflection Limit 0.08 mm (0.0031 in)
Drive Axle Deflection Limit 0.08 mm (0.0031 in)
shifter:
Shifter Type Guide bar
zarburetor:
Type/Manufacture x Quantity BD32/MIKUNIx 4
I.D. Mark 3BF-00 (Except for California)
3FH-00 (For California)
Main Jet (M.J.) #87.5
Main Air Jet (M.A.J.) #60
Jet Needle-Clip Position (J.N.) 5CFZ2
Needle Jet (N.J.) Y-O
Pilot Jet (P.J.) #I5
Pilot Outlet Size (P.O.) 0.85
Pilot Air Jet (P.A.J.) #130
Pilot Screw (P.S.) 3%
Valve Seat Size (V.S.) 1.2
Starter Jet (G.Sl) #27.5
(G.Sz ) 0.5
Bypass 1 (B.P. 1) 0.8
Bypass 2 (B.P. 2) 0.8
Throttle Valve Size (Th. V) #130
Fuel Level (F.L.) 4.5 - 6.5 mm (0.18 - 0.26 in)
Below from the float chamber line
2-7

MAINTENANCE SPECIFICATIONS pqjq
Lubrication System:
Oil Filter Type Paper
Oil Pump Type Trochoid pump
Tip Clearance 0.09 - 0.15 mm (0.0035 - 0.0060 in)
< Limit > < 0.2 mm (0.008 in) >
Side Clearance 0.03 - 0.08 mm (0.0012 - 0.0031 in)
< Limit > < 0.15 mm (0.006 in) >
Bypass Valve Setting Pressure 80- 1 2 0 kPa
(0.8 - 1.2 kg/cm’, 11.38 - 17.06 psi)
Relief Valve Operating Pressure 4 5 0 - 5 5 0 kPa
(4.5 - 5.5 kg/cm*, 63.99 - 78.21 psi)
ICooling System:
Radiator Core Size Width 325 mm (12.8 in)
Height 160 mm (6.3 in)
Thickness 32 mm (1.26 in)
Radiator Cap Opening Pressure 74 - 103 kPa (0.75 - 1.05 kg/cm*,
10.7 - 14.9 psi)
Reservoir Tank Capacity
< To Full level > 0.28 L (0.25 Imp qt, 0.30 US qt)
Water Pump
Type Single-suction centrifugal pump
Reduction Ratio 89141 x 48149 ( 2 . 1 2 6 )
2-8

Lubrication chart:
4 Pressured feed
+ Splashed
M Nozzle
Main journal bearing
1
Main journal bearing
Oil pan
Crankcase lightening Sequence:
Crankcase (Upper) Crankcase (Lower)
O-O.@ 8 mm Bolt: 24 Nm (2.4 m-kg, 17 ft.lb)

@-@,.@-86 mm Bolt: 12 Nm (1.2 m-kg, 8.7 ft*Ib)
2-9

MAINTENANCE SPECIFICATIONS (SPECI]
‘IGHTENING TORQUE
7
Part to be tightened Part name

Threat
Q’Q
Tightening torque 1
d
Remarks
size Nm II-&( ft. lb
Camshaft Cap Flange bol M6 24 10 1 .o 7.2

Cylinder Head Nut M8 12 25 2.5 18
Spark Plug - Ml0 4 13 1.3 9.4
Cylinder Head Cover Bolt M6 8 10 1 .o 7.2
Blind Plug (Sand) Screw Ml2 6 37 3.7 27
Blind Plug (Water) Screw M6 3 7 0.7 5.1
Connecting Rod Nut M7 8 23 2.3 17
Cam Chain Sprocket Bolt M7 4 24 2.4 17
c3
Cam Chain Tensioner Bolt M6 2 10 1 .o 7.2
Cam Chain Guide (Intake) Bolt M6 2 10 1.0 7.2
Cam Chain Tensioner End Cap bolt Ml1 1 20 2.0 14
Pipe Stopper Bolt M6 6 10 1 .o 7.2
Thermostat Housing Assembly Flange bof M6 1 10 1 .o 7.2
Thermostat Housing Cover Bolt M6 2 10 1 .o 7.2
Radiator Flange bol. M6 2 7 0.7 5.1
Water Pipe Joint Bolt M6 4 10 1.0 7.2
water Pump Bolt M6 2 10 1 .o 7.2
dater Pump Cover Bolt M6 2 10 1 .o 7.2
Radiator Cover Screw M5 4 5 0.5 3.6
Dil Pump Housing Screw M6 1 7 0.7 5.1
Dil Pump Mount Bolt M6 3 10 1 .o 7.2
Drain Plug Bolt Ml4 1 43 4.3 31
3il Delivery Pipe Bolt Ml0 2 20 2.0 14
sarburetor Joint Bolt M6 8 10 1 .o 7.2
Exhaust Pipe Nut M6 8 10 1 .o 7.2
Muffler Bracket Bolt M8 1 20 2.0 14
--IaaE
Exhaust Pipe Blind Plug (CO test) Bolt M6 4 10 1 .o 7.2
-1 E
Crankcase ‘lange boll M8 13 24 2.4 17
Crankcase Ilange boll M6 21 12 1.2 8.7
3il baffle plate Screw M6 4 7 0.7 5.1
Crankcase Cover (Left) Bolt M6 5 10 1.0 7.2
Crankcase Cover (Right) Bolt M6 10 10 1 .o 7.2
3earing Plate Bolt M6 2 10 1.0 7.2
3enerator Cover Bolt M6 5 10 1.0 7.2
starter Clutch Cover Bolt M6 7 10 1 .o 7.2
Q
starter Clutch :lange bolt Ml0 1 80 8.0 58
starter Clutch Outer and
Screw M6 3 10 1 .o 7.2
Starter Wheel
Vessure Plate Bolt M5 5 6 0.6 4.3
:lutch Boss Nut Ml8 1 70 7.0 51 Jse lock washe
‘ush Lever Screw M5 2 5 0.5 3.6 4
‘ush Rod Nut M6 1 16 1.6 11
Irive Sprocket Nut Ml8 1 70 7.0 51 Jse lock washe
jtopper Plate :lange bolt M6 1 10 1 .o 7.2 4
4.C. Magneto Bolt Ml0 1 80 8.0 58
itator Coil Bolt M6 3 10 1 .o 7.2
‘ickup Coil Screw M5 2 5 0.5 3.6
itarter Motor Bolt M6 2 10 1 .o 7.2
deutral Switch Screw M6 2 4 0.4 2.9
Iii Level Switch :lange bolt M6 2 7 0.7 5.1
2-10

MAINTENANCE SPECIFICATIONS 1-1
Chassis
4
Mnriel
. ..---.
F7R4lX-Nl/F7R4fKlSlIC
. -9. .-WV,. -.. .---- -
Steering System:
Steering Bearing Type Taper Roller Bearing
Front Suspension:
Front Fork Travel 130 mm (5.12 in)
Front Spring Free Length 412 mm (16.2 in)
< Limit > 408 mm (16.1 in)
Collar Length 160 mm (6.3 in)
Spring Rate: Kl 4.4 N/mm (0.5 kg/mm, 25.2 lb/in)
K2 6.6 N/mm (0.7 kg/mm, 37.5 lb/in)
Stroke Kl 0.0 - 90 mm (0.0 - 3.54 in)
K2 90 - 130 mm (3.54 - 5.12 in)
Optional Spring No
Oil Capacity 444 cm3 (15.6 Imp oz, 15 US oz)
Oil Level (Fully Compression) 92 mm (3.62 in)
Bellow the top of inner fork tube without
fork spring
Oil Grade Yamaha Fork Oil IOWT or equivalent
Rear Suspension:
Shock Absorber Travel 50 mm (I .97 in)
Spring Free Length 196.5 mm (7.74 in)
< Limit > 186.5 mm (7.34 in)
Fitting Length 174 mm (6.85 in)
Spring Rate Kl 98.1 N/mm (IO kg/mm, 560 lb/in)
Stroke Kl 0 - 50 mm (0.0 - 1.97 in)
Optional Spring No
Hard STD Soft
Adjusting 7 6 5 4 3 2 1
position
Swingarm:
Free Play Limit End 1 .O mm (0.04 in)
Side 1 .O mm (0.04 in)
Front Wheel:
Type Cast Wheel
Rim Size MT3.00 x 17
Rim Material Aluminum
Rim Runout Limit Radial 1 mm (0.04 in)
Lateral 0.5 mm (0.02 in)
qear Wheel:
Type Cast wheel
Rim Size MT4.00 x 18
Rim Material Aluminum
Rim Runout Limit Radial 1 mm (0.04 in)
Lateral 0.5 mm (0.02 in)
mhain:
Type/Manufacturer 428HVS/DAIDO
No. of Links 130
Chain Free Play 10 - 20 mm (0.4 - 0.8 in)
2-11

pqjq r
Model FZR400U/FZR400SUC -
:ront Disc Brake:

Type Dual
Disc Outside Diameter x Thickness 282x4mm (ll.lOx0.16in)
< L i m i t >* 0.5 mm (0.02 in)
< L i m i t >* 0.5 mm (0.02 in)
.: ::. . . . ,‘ ;:;;. . ;. ; : *
4
Caliper Cylinder Inside Diameter: 42.85 mm (1.69 in)
Brake Fluid Type DOT#4orDOT#3
Rear Disc Brake:

Single
Type
Disc Outside Diameter x Thickness 210 x 5 mm (8.27 x 0.20 in)
< L i m i t >* 0.5 mm (0.02 in)
< L i m i t >* 0.5 mm (0.02 in)
.: ::. . ..‘,’ ::;:. I ,‘, .;: *

4

Caliper Cylinder Inside Diameter 38.18 mm (1.5 in)
Brake Fluid Type DOT #4 or DOT #3
Clutch Lever:
Clutch Lever Free Play
10 - 15 mm (0.4 - 0.6 in)
Brake Lever and Brake Pedal:
Brake Lever Free Play 2 - 5 mm (0.08 - 0.20 in)
Brake Pedal Position 42 mm (1.7 in)
Bellow the top of the footrest.
2-12

MAINTENANCE SPECIFICATIONS (SPECII
Tightening torque
Part to be tightened Thread size
Nm me kg ft. lb
~.__
Front Axle and Outer Tube M14x 1.5 58 5.8 42
Rear Axle and Nut M16x 1.5 107 ’ 10.7 77
Handlebar Crown and Inner Tube M8 x 1 . 2 5 26 2.6 19
Handlebar Crown and Steering Stem M22 x 1.0 110 11.0 80
Brake Caliper (Front/Rear) MlOx 1.25 35 3.5 25
Bleed Screw and Brake Caliper M8 x 1 . 2 5 6 0.6 4.3
Brake Hose and Union Bolt MlOx 1.25 26 2.6 19
Front Master Cylinder and Master Cylinder Holder M6 x 1.0 9 0.9 6.5
Front Master Cylinder and Cylinder Cap M5 X 0.8 2 0.2 1.4
Front Fender and Outer Tube M6 x 1.0 6 0.6 4.3
Handlebar and Inner Tube MB xl.25 23 2.3 17
Engine Mounting: Front MlOx 1.25 55 5.5 40
Rear - Upper MlOx 1.25 55 5.5 40
Rear - Lower MlOx 1.25 45 4.5 32
Down Tube and Frame: Front MlOx 1.25 60 6.0 43
Rear MB x 1.25 33 3.3 24
Footrest Bracket and Frame MB x 1.25 28 2.8 20
Pivot Axle and Nut M14x 1.5 90 9.0 65
Relay Arm and Frame MlOx 1.25 40 4.0 29
Arm and Swingarm MlOx 1.25 40 4.0 29
Arm and Relay Arm MlOx 1.25 40 4.0 29
Swingarm and Frame Ml0 x 1.25 40 4.0 29
Rear Shock Absorber Ml0 x 1.25 40 4.0 29
Footrest and Footrest Bracket Ml0 x 1.25 57 5.7 41
Rear Footrest Bracket and Frame MB x 1.25 20 2.0 14
Rear Master Cylinder and Rear Arm Bracket MS x 1.25 20 2.0 14
Cowling and Stay M6 x 1.0 4 0.4 2.9
Tension Bar and Brake Caliper Bracket MB x 1.25 28 2.8 20
Front Fork Pinch Bolt M8 x 1 . 2 5 20 2.0 14
Sprocket and Clutch Hub MB x 1.25 32 3.2 23
Brake Disc and Clutch Hub M8 x 1 . 2 5 20 2.0 74
Inner Tube and Steering Stem M8 x 1 . 2 5 22 2.2 16
Frame and Rear Frame: Upper MlOx 1.25 64 6.4 46
Lower Ml2 x 1.25 aa a.8 64
2-13

MAINTENANCE SPECIFICATIONS -1
Electrical
1
Voltage: 12v
Ignition System:
Ignition Timing (B.T.D.C.) IO” at 1,300 r/min
Advanced Timing (B.T.D.C.) 48” at 6,500 r/min (3BF), 38” at 3,500 r/min
(3FI-i)
Advancer Type Electrical
3BF: 3FH:
IlllllillLU 0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 314 15
0 1 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3 1 4 15
Engine Speed (x IO3 r/min) Engine Speed (x IO3 r/min)
T.C.I.:
Pickup Coil Resistance 85 - 115s2 at 20°C (68°F)
(Color) (White/Red -White/Black)
T.C.I. Unit/Manufacturer TID14-53A/HITACHI (3BF)
TIDl4-63A/HITACHI(3FH)
Ignition Coil:
Model/Manufacturer CM12-30/HITACHI
Minimum Spark Gap 6 mm (0.24 in)
Primary Winding Resistance 1.8 -2.2s2 at 20°C (68°F)
Secondary Winding Resistance 9.6 - 14.4kR at 20°C (68°F)
Spark Plug Cap Resistance IOkR
Charging System:
Type A.C. Magneto Generator
A.C. Generator:
Model/Manufacturer FL118-13/HITACHl
Nominal Output 12V, 18A at 5,000 r/min
Stator Coil Resistance 0.44 - 0.66n at 20°C (68” F)
Voltage Regulator:
Type Semi conductor - short circuit
Model/Manufacturer SH569bHINDENGEN
No Load Regulated Voltage 14.3 - 15.3v ~...___
Battery:
Capacjty 12u, 12AH
Specific Gravity 1.280
2-14
MAINTENANCE SPECIFICATIONS j?391
(SPECI
Electrical Starter System:
Type Constant mesh type
Starter Motor:
Model/Manufacturer SM-7/M ITSUBA
output 0.4kw
Armature Coil Resistance OLT at 20°C (68°F)
Brush - Overall Length 11 mm (0.43 in)
< Limit > 5 mm (0.20 in)
- Spring Force 540 - 660 g (19.05 - 23.28 oz)
Commutator Dia. 23 mm (0.91 in)
Wear Limit 22 mm (0.87 in)
Mica Undercut 1.8 mm (0.07 in)
Starter Switch:
Model/Manufacturer A104-128/HITACHI
Amperage Rating 1 OOA
iorn:
Type/ Plane Type/l PCS.
Model/Manufacturer MF-12/NIKKO
Maximum Amperage 1.5A
=lasher Relay (Relay Assembly):
Type Semi transistor type
Model/Manufacturer FX257N/NIPPOND E N S 0
Self Cancelling Device Yes
Flasher Frequency 60 - 120 cycle/min
Wattage 27W x 2 pcs + 3.4W
sidestand Relay:
Model/Manufacturer G4MW-l12lT-010-Y17/OMRON
Coil Winding Resistance 67.5 - 82.5R at 20°C (68°F)
Diode No
3il Level Switch:
Model/Manufacturer 1 WG/NlPPON DENS0
starting Circuit Cut-Off Relay:
Model/Manufacturer G4MW/OMRON
Coil Winding Resistance 67.5 - 82.5s2 at 20°C (68°F)
Diode No
-uel Pump Relay:
Model/Manufacturer G4MW/OMRON
Coil Winding Resistance 67.5 - 82.5n at 20°C (68°F)
Color Code Black
Electric Fan:
Model/Manufacturer NAAB08/NIPPON DENS0
rhermostat Switch:
Model/Manufacturer 47X/NIPPON THERMOSTAT
rhermo Unit:
Model/Manufacturer 1 lH/NIPPONSEIKI
zircuit Breaker:
Type Fuse
Amperage for Individual Circuit x Quantity:
MAIN 30A x 1
HEADLIGHT 10Ax 1
SIGNAL 10Ax 1
IGNITION lOAx
RESERVE 10Ax 1,30Ax 1
2-15

GENERAL TORQUE SPECIFICATIONS [+q-jqq
GENERAL TORQUE SPECI FICA- General torque
TIONS specifications
(NAut)
This chart specifies torque for standard fasteners Nm m-kg ft. lb
with standard I.S.O. pitch threads. Torque 10 mm 6mm 6 0.6 4.3
specifications for special components or assem- 12mm 8mm 15 1.5 11
blies are included in the applicable sections of 14 mm 10 mm 30 3.0 22
this book. To avoid warpage, tighten multi-
17 mm 12 mm 55 5.5 40
fastener assemblies in a crisscross fashion, in
19 mm 14mm 85 8.5 61
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications 22 mm 16 mm 130 13.0 94
call for clean, dry threads. Components should
be at room temperature.
A: Distance across Hats

B: Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure

mm millimeter 10e3 meter Length
cm centimeter lo-’ meter Length
kg kilogram lo3 gram Weight
N Newton 1 ka x m/se? Force
Nm Newton meter Nxm Torque
m-kg Meter kilogram m x kg Torque
Pa Pasta I N/m2 Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter
Volume or Capacity
cm3 Cubic centimeter
r/min Rotation per minute Engine Speed
2-16

LUBRICATION POINT AND GRADE OF LUBRICANT piqjqq
LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication Point I Symbol

Oil seal lip
O-Ring
Bearing
Piston surface
Piston pin
Cylinder head bolt
Crankshaft pin
Crankshaft journal
Connecting rod bolt/Nut
Camshaft cam lobe/Journal
Valve stem (IN, EX)
Valve stem end (IN, EX)
Valve lifter
Water pump impeller shaft
Oil pump rotor (Inner/Outer), housing
Oil strainer assembly
Idle gear surface/Bearing
Starter idle gear
Starter idle gear shaft
Primary driven gear
Transmission gear (Wheel/Pinion)
Axe (Main/Drive)
Push lever assembly
Push rod
Shift cam
Shift fork/Guide bar
Shift shaft assembly
Neutral switch O-Ring
2-17

LUBRICATION POINT AND GRADE OF LUBRICANT l=l P9I
CHASSIS
Lubrication Point
Steering bearing (Upper/Lower)

Wheel bearing/Axle
Front wheel oil seal (Right/Left)
Rear wheel oil seal ,
Clutch hub oil seal
Clutch hub fitting area
Rear brake pedal shaft
Change pedal
Side stand sliding surface
Tube guide (Throttle grip) inner surface
Brake lever bolt, sliding surface
Clutch lever bolt, sliding surface
Rear shock absorber (Upper/Lower)
Swingarm pivot bearing
Pivot shaft
Arm bearing
Thrust cover (Inner)
Swingarm bearing (Inner)
Rear footrest ball
Rear footrest pin
2-18

ISPEC(l
LUBRICATION DIAGRAM
LUBRICATION DIAGRAM
@ Oil filter
@ Oil strainer
@ Oil pump

COOLANT DIAGRAM p$Ql
COOLANT DIAGRAM
@ Radiator
@ Water pump
@ Thermostat housing
@Thermostatic valve
@ Radiator cap
Q
5
2-20

CABLE ROUTING pqj$q
CABLE ROUTING (‘I)

h] Insert the clutch cable into the frame inner hole.
@ Band
@ Throttle cables
@ Brake hose
@ Clutch cable
2-21

CABLE ROUTING bpEcl p91
CABLE ROUTING (2)
@ Brake hose m Pass the handlebar switch lead (Left) behind the
@ Clamp inner tube
•I To headlight unit
a To flasher light (Left)
a To flasher light (Right)

CABLE ROUTING
CABLE ROUTING (3)
2-24

CABLE ROUTING -1
@Speedometer assembly To handlebar switch (Left)
@ Headlight unit To clutch lever
@Horn Pass the speedometer cable outside the inner tube.
@Brake hose To air filter case
($ Clamp To fuel tank
@Front brake caliper (Left) To fuel pump
0 Speedometer cable Pass the sidestand switch lead inside the water pipe.
@Clutch cable To oil lever gauge
@Ignition coil lead (Left) Get these cords together, put them in the recess on
@Starter cable the left inside of the frame, and place the cover on
asidestand switch them.
@Air vent hose Fasten the lead and the rectifier/regulator together.
@Rectifier/Regulator lead Fasten the lead under the water pump installing bolt.
@Band To neutral lead
@Canister (For California only)
2-25

CABLE ROUTING
j?39I
bPECl
CABLE ROUTING (4)
2-26

CABLE ROUTING
@Brake hose (Right) ?? To radiator cap assembly
@Clamp ? Pass the spark lead and fan motor lead along the air
@ Ignition coil (Right) guide groove.
@Spark lead (Right) ? Pass the recovery tank hose on the fuel tank bracket.
@Air guide ? Pass on the inside of the water pipe the carburetor
@ Recovery tank hose air vent hose on the side of the #l and #2 cylinders,
0 Fuel hose and clamp this hose together with the carburetor
@Water pipe air vent hose on the side of the #3 and #4 cylinders.
@ Breather hose (Fuel tank) Then let these hoses go down in front of the starter
@I Rear brake reservoir tank motor.
@) Rear brake switch ?? To fuel pump.
@Rear brake switch lead m Pass breather hose (Fuel tank), Breather hose (Recovery
@Rear brake hose tank) and carburetor air vent hose inside the relay arm.
@ Breather hose (Recovery tank)
@Recovery tank

CABLE ROUTING ISPEC(l
CABLE ROUTING (5)
2-28

CABLE ROUTING (SPECII
@ Fuel pump relay To fuel pump
@ Ignition coil (Right) Pass the starter motor lead under the starter motor.
COS tarter motor Pass on the inside of the water pipe the carburetor
@Clamp air vent hose on the side of the #I and #2 cylinders,
@ Rear brake switch lead and clamp this hose together with the carburetor air
@Breather hose (Recovery tank) vent hose on the side of the # 3 and #4 cylinders.
0 Rear brake master cylinder Then let these hoses go down in front of the starter
@Main fuse motor.
@Recovery tank To clutch lever
@Sidestand relay Locate the wire harness with its white taped portion
@) Digital ignitor unit in line with the hole on the inside of the tank rail.
@ Diode assembly To headlight unit
@Rectifier/Regulator
@Battery
@Battery (-1 terminal
@Canister (For California only)
@Starter lead
@Generator lead
@Clutch cable
@ignition coil (Left)
@Therm0 unit
@Relay assembly
@Exup servo motor (For California only)
@Exup control unit (For California only)
2-29

INTRODUCTION/MAINTENANCE INTERVALS CHART LEIBil
ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap-
plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
MAINTENANCE INTERVALS CHART

Proper periodic maintenance is important. Especially important are the maintenance services related
to emissionscontrols. These controls not only function to ensure cleaner air but are also vital to proper
engine operation and maximum performance. In the following maintenance tables, the services related
to emissions control are grouped separately.
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

Initial Odometer readings
** xx XX
1 2 3
1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 kr
IO. Item Remarks
or or or or or or
1 month 7 months 13 months 19 months 25 months 31 month
( 6 0 0 mi) (4,400mi) (8,200mi) (12,OOOmi) (15,800mi) (19,600m
Check and adjust valve
Valve clearance when engine is 0
I*
clearance cold.
Check condition. Adjust
gap ahd clean. Replace at
Spark 0 0 0
13,000 km (or 13 months) Replace Replace
- Plug and thereafter every
12,000 km (or 12 months).
Crankcase Check ventilation hose for
I” ventilation cracks or damage. 0 0 0 0 0
system Replace if necessary.
Check fuel hose and
IX Fuel line vacuum pipe for cracks 0 0 0 0 0
or damage. Replace if
necessary.
Replace initial 31,000 km
i” Fuel filter (19,600 mi) and thereafter Replace
every 30,OOOkm (I 9,OOOmi).
Check for leakage. Retigh-
is Exhaust ten if necessary. Replace 0 0 0 0 0
system gasket(s) if necessary.
Carburetor
‘* synchroni- Adjust synchronization of “0 0 0 0 0 0
zation carburetors.
Check and adjust engine
lx Idle speed idle speed. Adjust cable 0 0 0 0 0
free play.
e ;r r.-.rnmm,-,..A,A +L.,+ +L.,.^,. :A,.-^ L^ ^^..., :--^I L.. ^ “..--L- A^..,^.. -I --Le.. -.._I:I!-A ----L- :-
NOTE :
For father odometer reading, repeat the above maintenance at the period established; ““I: Every
6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi), and **3: Every 24,000 km (15,200 mi)
intervals.
3-1

MAINTENANCE INTERVALS CHART AD J m
I1NSPI
GENERAL MAINTENANCE/LUBRICATION
Initial Odo meter readir w l-
??? ** xx
1 2 3
,000 km 7,000 km ‘3,000 km 19,000 krr I I 25,000 krr I I31,000 kn
JO. Item Remarks Tvw
or
1 mOdnth 7 months 3 ZAnths 19 m%thr i #25 i:nths 31 z&th!
:600 mi) 4,400 mi) 8,200 mi) ( 12,000 mi I( 15,800mi ii 19,600 mi
-
*l)Yamalube
4-cycle oil or
SAE 2OW40
Warmup
type “SE”
engine
1 Engine oil motor oil 0 0 0 0 0 0
before
‘2)SAE
draining
lOW30 type
“SE” motor
oil
7
2 - 0 0
Oil filter Replace.
- - -
Clean with
compressed - 0 0 0 0
3” Air filter
air. Replace
if necessary.
-
Check hose
for cracks
or damage, - 0 0 0 0
Cooling replace if
4
system necessary.
Replace Ethylene glycol
coolant anti-freeze Replace
- 24 months. coolant
Adjust free
Brake play. Replace 0
5” - 0 0 0 0
system pads if
necessary.
Check chain
condition.
SAE
Drive Adjust and Every 500 km (300 mi)
6 3ow-5ow
chain lubricate
motor oil.
chain
- thoroughly.
Yamaha chain
Control Apply chain and cable
7 and meter lube lube or SAE 0 0 0 0 0
cable thoroughly. 1 OW30 motor I
oil.
-
Rear arm
I
pivot shaft Apply
Lithium soap 0
8” and rear grease
base grease.
suspension lightly.
- link pivots.
Yamaha chain
Brake/
APP~V and cable
clutch 0 0 0
9 chain lube lube or SAE
lever pivot
lightly. 1 OW30 motor
shaft
oil.
-
Yamaha chain
Brake Lubricate.
and cable
pedal and APP~V 0 0 0
0 lube or SAE
change chain lube
1 OW30 motor
pedal shafi lightly.
oil.
i
3-2

initial Odometer readings
xx 1 xx 2 ** 3
JO. Item Remarks Type 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 krrI
or or or or or or
1 month 7 months 13 months 19 months 25 months 31 months
(600 m i ) (4,400 m i ) (8,200 m i ) (12,OOOmi) (15,800mi) (19,600mi 1
Check
Yamaha chain
operation
and cable
Side stand and lube or SAE 0 0 0 0 0
II”
pivot lubricate.
1 OW30 motor
Apply chain oil
lube lightly. ’
Check opera- Yamaha Fork
12” Front tion and Oil IOWT or 0 0 0 0 0
fork oil
leakage. equivalent
Check bear-
ings assembly M e d i u m
for looseness.
,3* Steering Moderately weight wheel 0 0 0 Repack 0
bearing bearing
repack every
24,000 km grease.
(15,000 mi).
Check bear-
,4* Wheel ings for - 0 0 0 0 0
bearings smooth
rotation.
Check speci-
fic gravity
15 Battery and breather - 0 0 0 0 0
pipe forpro-
per operation.
Check and
16++ Sidestand clean or 0 0 0 0 0 0
switch replace if
necessary.
d
“I) If ambient temperature does not go below 5°C (41yF).
“2) If ambient temperature does not go below 15°C (59°F).
*It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
NOTE:
For farther odometer reading, repeat the above maintenance at the period established, ““1: Every
6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi) and **3: Every 24,000 km (15,200 mi)
intervals.
3-3

I’
COWLINGS REMOVAL AND INSTALLATION
COWLING REMOVAL AND

INSTALLATION
REMOVAL
1. Remove:
?? Lower cowling (Left)
2. Remove:
?? Lower cowling (Right)
3. Remove:
?? Center cowling (Left)
4. Remove:
?? Center cowling (Right)

5. Remove:
?? Rear view mirrows (Left and right)
9. Remove:
0 Upper cowling

COWLINGS REMOVAL AND INSTALLATION ADJ m
I’NSPI
10. Remove:
??Seat
NOTE:
To open the seat lock, insert the key in the
lock and turn it clockwise.
11. Remove:
??Top cover
INSTALLATION
Reverse the “REMOVAL” procedure.
1. install:
?? Seat
NOTE:
?? Make sure that the seat is securely fitted.
?? When reinstalling the seat, insert the lobes on

the seat front into the receptacles on the
frame, then push down the seat.
3-6

EXUP CABLE ADJUSTMENT (For
ENGINE
EXUP CABLE ADJUSTMENT (For California
only)
1. Remove:
0 Lower cowling (Left)
?? Seat
Refer to the “COWLINGS REMOVAL

AND INSTALLATION - REMOVAL”
section.
2. Remove:
?? Valve cover @
3. Turn on the main switch.
NOTE:
If does not operate EXUP servo motor, refer
to the “YAMAHA EXHAUST VARIABLE
VALVE SYSTEM” section in the CHAPTER 8.
4. Check:
?? Alignment mark @
Not aligned + Adjust EXUP cables.
5. Adjust:
?? EXUP cables
Adjustment steps:
?? Loosen both locknuts @ and turn in both
adjuster @ .
@Insert a [$4 mm (~0.16 in)] pin @ through
the aligning indent in the pulley and into
the hole.
?? Turn both adjusters, counterclockwise so
that the cables free play becomes Zero mm
(Zero in) with fingers.
??Turn both adjuster l/2 turn clockwise.
?? Tighten the locknuts.
Locknuts:
8 Nm (0.8 m-g, 5.8 ft.lb)
?? Remove the pin.

?? Turn on the main switch and, check that
the alignment mark is aligned. If not,
repeat the above step.
3-7

VALVE CLEARANCE ADJUSTMENT AD J @!!!iii
llNSPl
7. Install:
0 Valve cover 0
I\ A Bolts
I (Valve Cover):
10 Nm (1.0 m-kg, 7.2 ft.lb)
VALVE CLEARANCE ADJUSTMENT
The engine must be cool before servicing the

valve clearance.
NOTE:
Measure and adjust valve clearance when piston
is at TDC on compression stroke.
REMOVAL
1. Remove:
?? Lower cowlings (Left and Right)
?? Center cowlings (Left and Right)
?? Seat
Refer to the “COWLING REMOVAL AND
INSTALLATION - REMOVAL” section.
2. Remove:
?? Fuel tank
Refer to the “ C A R B U R E T O R - R E -
MOVAL” section in the CHAPTER 6.
3. Place a drain pan under the drain bolts.
4. Remove:
??Drain bolt (Outlet pipe) @
@Drain bolt (Cylinder) @
3-8

VALVE CLEARANCE ADJUSTMENT AD J @iii
Pn
5. Remove:
?? Radiator cap @
6. Drain:
0 Cooling system
Refer to the ‘“COOLANT REPLACE.
MENT” section.
7. Disconnect:
?? Fan motor coupler @
8. Disconnect:
?? Hose (Radiator - Inlet)
?? Hose (Radiator - Outlet)
9. Remove:
?? Radiator
10. Remove:
?? Spark plug leads
?? Cylinder head cover
?? Generator cover
Valve Clearance Measurement

1. Measure:
0 Valve clearance
Valve clearance measurement steps:

?? Turn the crankshaft counterclockwise.
?? Align the “T” mark @ on the magneto with
the crankcase end @ when #l piston is at

TDC on compressionstroke.
3-9

UOTE:
EX IN Compression T.D.C. can be found when the
:am lobes are apart from each other, as
;hown.
B Measure the valve clearance using Thickness

Gauge @ .
Out of specification+ Adjust valve clearance.
Intake Valve (Cold):

0.11 - 0.20 mm (0.004 - 0.008 in)
Exhaust Valve (Cold):
0.21 - 0.30 mm (0.008 - 0.012 in)
?? Record the measured amount if the clearance

is incorrect.
*Measure the valve clearance in sequence,
for #2, 4 and #3 cylinders.
Out of specification + Adjust valve clearance.
Firing Sequence:
#1+#2+#4+#3
8 Front
NOTE:
Turn crankshaft each degrees counterclock.
wise from #l Cylinder TDC.
, A
0; 18;’ 36;’ 547 7;“’
?? Crankshaft counterclockwise turning angle

?? Cylinder
#l
H
@ Combustion
#2
0
#3
84
Adjusting Pad Replacement

1. Remove:
?? Cam chain tensioner
?? Chain guide (Upper)
?? Chainguide (Exhaust side)
0 Cam caps
?? Cam chain
?? Cam shafts
3-10

VALVE CLEARANCE ADJUSTMENT AD J @iii
IEn
Refer to the “ENGINE DISASSEMBLY CAM-

SHAFT AND CYLINDER HEAD - Procedure
2”, in the CHAPTER 4.
Fasten the wire to the cam chain to prevent it
from falling into the crankcase.
2. Remove:
0 Valve lifter 0
?? Pad
Use valve lapper @

Record the installed pad number.
NOTE:
?? Place a piece of rug in the cam chain room
to prevent the pad from falling into the
crankcase.
?? Remove the rug after adjustment.
3. Select:
?? Proper pad
Proper pad selection steps:

?? Select the proper pad from the table:
Pad Availability:
Pad range
25 increments
1.20 mm
No. 120 Pads stepped in
(0.047 in)
2 4. mm p.05 mm (0.002 in)
No. 240 Increments
id.094 in)
NOTE:
Thickness @ of each pad is marked on the
pad side wall.
?? Round off the hundredths digit of the

installed pad number to the nearest 0.05
mm increment.
3-11

VALVE CLEARANCE ADJUSTMENT AD J =
PEI
EXAMPLE:
Installed pad number = 148 (1.48 mm)
Rounded off digit = 150
NOTE:
Pads can only be selected in 0.05 mm (0.002
in) increments.
?? Locate the “Rounded off Pad Number” on

the chart, and then find the measured valve
clearance. The point where these coordinates
intersect is the new pad number.
NOTE:
Use the new pad number as a guide only as
the number must be verified.
4. Install:
@Pad (New) @
5. Install:
aValve lifter @
NOTE:
?? Apply molybdenum disulfide grease to the pad.
?? Valve lifter must be rotated smoothly by a
finger.
5. Install:
?? Camshafts @
?? Cam chain
a Camshaft caps @
Bolts (Camshaft Cap) :

10 Nm (1.0 me kg, 7.2 ft.lb1
NOTE:
?? Installthe exhaust camshaft first.
?? Align the matching marks @ .
*Apply molybdenum disulfide grease to the

camshafts and cam caps.
3-12

INTAKE
235 240
220 225
I---I -I 225 230
._ .__ .-- ~170~175~180~185[190~195~200~205~210~215~220~225~230 235
FARANCE
TitiJ-
VALVE CLEARANCE (cold):

0.11 - 0.20 mm (0.004 - 0.008 in)
Example: Installed is 170
Measured clearance is 0.24 mm (0.009 in)
Replace 170 pad with 180 pad
EXHAUST
i0 155 160 1651170 175 180 185 190 195~200~205~210~215
roll75 180118511901195 200 205 210~215~220~225~230~23E
ZOO 205 210 215 220 225 230 235 1240

)512001205 210 215 220 225 230 235 2401
)]195[200~205~210 215 2x0 2?5,230 235 240
VALVE CLEARANCE (cold):

0.21 - 0.30 mm (0.008 - 0.012 in)
Example: installed is 175
Measured clearance is 0.35 mm (0.014 in)
Replace 175 pad with 185 pad
3-13

1’““‘11 -
VALVE CLEARANCE ADJUSTMENT ADJ m
NOTE:
??Refer to the “ENGINE ASSEMBLY AND AD-
JUSTMENT - CYLINDER HEAD AND
CAMSHAFT” section in the CHAPTER 4.
?? Turn the carnkshaft counterclockwise several
turns for the installed parts to settle into the
correct position.
6. Measure:
0 Valve clearance
Valve clearance verification steps:

?? Follow the valve clearance measurement
steps.
?? If the clearance is incorrect, repeat all
Adjusting Pad Replacement steps until the
proper clearance is obtained.
INSTALLATION
1. Install:
NOTE:
Install the cam chain tensioner with the “UP”
mark facing upward.
Bolts (Cam Chain Tensioner):

IO Nm (1.0 m-kg, 7.2 ft.lb)
2. Install:
aGuide collar @
@Spring @
?? Washer @
*Cam chain tensioner cap @

CARBURETOR SYNCHRONIZATION ADJ m I
FNSPl
3. Recheck:
?? Align the matching marks @ .
4. Install:
?? Chain guide (Upper) @
?? Chain guide (Exhaust side) @I
Bolts (Chain Guide):

10 Nm (1.0 m-kg, 7.2 ft.lb) I
5. Install:
Bolts (Cylinder Head Cover):

10 Nm (1.0 m-kg, 7.2 ft-lb)
6. Fill:
?? Cooling system
Coolant Total Amount

(Including All Routes):
1.9 L (1.7 Imp qt, 2.0 US qt)
CARBURETOR SYNCHRONIZATION
Carburetors must be adjc;sted to open and close
simultaneously.
Valve clearance must be set properly before

synchronizing the carburetors.
3-15

CARBURETOR SYNCHRONIZATION AD J m
PEI
1. Remove:
aCenter cowlings
0 Seat
2. Remove:
?? Fuel tank
Refer to the “CARBURETOR - RE-

3. Remove:
*Vacuum plugs @
4. Install:
0 Vacuum gauge
?? Sub tank
Vacuum Gauge:
P/N Y U-08030
5. Start the engine and let it warm up.
6. Adjust:
?? Idle speed
Turn the throttle stop screw @

.
Turn in Engine speed is increased.
Turn out Engine speed is decreased.
Idle Speed: 1,250 - 1,350 r/min

I
7. Adjust:
?? carburetors synchronization
Carburetor synchronization adjustment steps:

?? Lift up the front of fuel tank
?? synchronize carburetor No. 1 to carbure-
tor No. 2 by turning synchronizing screw @
until both gauges read the same.
3-16

p&q--j
IDLE SPEED ADJUSTMENT AD J m
*Racing the engine for less than a second,
two or three times, and check the syn-
chronization again.
Vacuum Pressure at Idle Speed:

21.33 f 0.6 kPa
(160 * 5 mmHg, 6.30 f 0.2 inHg)
Vacuum Synchronous Difference:
I 1.33 kPa (10 mmHg, 0.4 inHg)
oRepeat the above steps to synchronize

carburetor No. 4 to carburetor No. 3 by
turning synchronizing screw @ until both
gauges read the same.
*Repeat the same steps to synchronize No.
2 carburetor to No. 3 carburetor by turn-
ing synchronizing screw @ until both
gauges read the same.
8. Adjust:
?? Idle speed
9. Install:
0 Vacuum plug
?? Fuel tank
0 Seat
*Center cowlings
IDLE SPEED ADJUSTMENT

1. Start the engine and let it warm up.
2. Inspect:
?? Idle speed
Out of specification --f Adjust.
Idle Speed: 1,250 - 1,350 r/min
3. Adjust:
?? Idle speed
.Turn the throttle stop screw @
Turn in
Turn out
Engine speed is increased.
Engine speed is decreased.
1
THROTTLE CABLE FREE PLAY ADJUSTMENT
THROTTLE CABLE FREE PLAY ADJUST-
MENT
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
1. Check:
?? Throttie cable free play @
Out of specification -+ Adjust.
Throttle Cable Free Play

(Throttle Grip)@:
2 - 5 mm (0.08 - 0.20 in)
2. Adjust:
?? Throttle cable free play
Throttle cable adjustment steps:

?? Remove the seat, top cover and air filter
case.
Refer to the “CARBURETOR - REMO-
VAL”section in the CHAPTER 6.
?? Loosen the locknut (Throttle cable 1) @ .
?? Turn the adjuster (Throttle cable 1) @

clockwise or counterclockwise until proper
free play (Throttle grip) is attained.
@Throttle cable 2
I
*Tighten the locknut @

?? If the free play is incorrect, adjust the
throttle cable free play with the adjuster

(Throttle grip side).
?? Loosen the locknut (Throttle cable 1 -
Throttle grip side) @ .
?? Turn the adjuster (Throttle cable 1 -
Throttle grip side) 0 clockwise or counter-
clockwise until proper free play (Throttle
grip) @is attained.
3-18

SPARK PLUG INSPECTION

(Throttle Grip) @ :
I 2 - 5 mm (0.08 - 0.20 in)
I ?? Tighten the locknut @ . I
NOTE:
Normally, once the throttle cable length adjuster
(carburetor) is properly set; the only adjustment
required is maintenance of free play at the
throttle cable length adjuster (Throttle grip).
SPARK PLUG INSPECTION

1. Inspect:
?? Electrode @
Wear/ Damage-t Replace.

*Insulator color @
Normal condition is a medium to light tan
color.
Distinctly different color-+Check the engine
377 ooo condition.
@ Spark plug gap
2. Clean:
*Spark plug
Clean the spark plug with a spark plug
cleaner or wire brush.
3. Inspect:
*Spark plug type
Incorrect4 Replace.
Standard Spark Plug:

CR8E (NGK),
U24ESR-N (NIPPON DENSO)
3-19

IGNITION TIMING CHECKS AD J =
LINSPI
4. Measure:
*Spark plug gap
Out of specification * Regap.
Use a wire gauge.
Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.032 in)
5. Tighten:
*Spark plug
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
.
Spark Plug:
13 Nm (1.3 m-kg, 9.4 ftelb)
NOTE:
If a torque wrench is not available when you are
installing a spark plug, a good estimate of the cor-
rect torque is l/4 to l/2 turns part finger tight.
Have the spark plug torqued to the correct value
as soon as possible with a torque wrench.
IGNITION TIMING CHECK

1. Remove:
?? Center cowling
2. Remove:
?? Generator cover
3. Connect :
*Timing light @
To the $1 spark plug lead.
?? Inductive tachometer
Timing Light:
P/N Y U-33223
Inductive Tachometer:
P/N YU-08037
3-20

COMPRESSION PRESSURE MEASUREMENT AD J m
[INSPI
4. Warm up the engine and allow it to idle at
the specified speed.
Engine Idle Speed:

1,250 - 1,350 r/min
5. Check:
0 Ignition timing
Visually check the crankcase end @ is
within the firing range @ on the magneto.
Out of firing range -+ Check pickup as-
sembly.
NOTE:
Ignition timing is not adjustable.
6. Install:
?? Generator cover
COMPRESSION PRESSURE MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1. Measure:
0 Valve clearance
Refer to the “VALVE CLEARANCE AD-
JUSTMENT” section.
2. Warm up the engine.
3. Remove:
*Spark plugs
4. Remove:
?? Center cowling (Left)
Refer to the “ C O W L I N G R E M O V A L
3-21

COMPRESSION PRESSURE MEASUREMENT
*Crank over the engine with the electric starter
(be sure the battery is fully charged) with the
throttle wide open until the compression
reading on the gauge stabilizes.
*Check readings with specified levels (See
chart).
Compression Gauge:
P/N YU-33223
Compression Pressure (At sea level) :

Standard :
950 kPa (9.5 kg/cm2, 138 psi)
Minimum:
750 kPa (7.5 kg/cm2, 109 psi)
Maximum:
1,150 kPa (11.5 kg/cm*, 164 psi)
When cranking the engine, ground spark

plug lead to prevent sparking.
*Repeat the previous steps for the other

cylinders.
‘If pressure falls bellow the minimum level:
1) Squirt a few drops of oil into the affected
cylinder.
2) Measure the compression again.
Compression Pressure
(with oil introduced into cylinder)
Reading Diagnosis
Higher than Worn or damaged pistons
without oil
VOTE:
The difference between the highest and lowest
zylinder compression readings must not vary
nore than the specified value.
Difference Between Each Cylinder:

Less than 100 kPa (1 kg/cm*, 15 psi)
3-22

ENGINE OIL LEVEL INSPECTION/
ENGINE OIL REPLACEMENT
ENGINE OIL LEVEL INSPECTION
1. Place the motorcycle on its centerstand and
warm up the engine for several minutes.
NOTE:
Position motorcycle straight up when checking
oil level, a slight tilt to the side can produce
false readings.
2. Stop the engine and visually check the oil

level throught the level window @ .
3. Inspect:
??0il level
Oil level should be between maximum @
and minimum @ marks.
Low oil level --f Add oil to proper level’.
NOTE:
Wait a few minutes until level settles before
inspecting.
Recommended Engine Oil:

At 5°C (40” F) or Higher:
Yamalube 4-cycle oil or
SAE 2OW40 Type SE Motor Oil
At 15°C (60°F) or Lower:
SAE lOW30 Type SE Motor Oil
0 5 10 15°C
ENGINE OIL REPLACEMENT

1. Warm up the engine for serveral minutes.
2. Place a drain pan under the engine.
3. Remove:
4. Remove:
0 Oil filler cap
5. Remove:
?? Drain plug @
Drain the engine oil.
6. Tighten:
?? Drain plug @
Oil Drain Plug:
43 Nm (4.3 mmkg, 31 ft-lb)
3-23

ENGINE OIL FILTER REPLACEMENT ADJ m
PII
7. Fill:
@Crankcase
A CAUTION:
Do not allow foreign material to enter the

crankcase.
Periodic Oil Change:

2.7 L (2.4 Imp qt. 2.9 US qt)
Recommended Engine Oil:
At 5°C (40” F) or Higher:
Yamalube 4-cycle oil or
SAE 2OW40 Type SE Motor Oil
At 15°C (60°F) or Lower:
SAE lOW30 Type SE Motor Oil
8. Install:
0 Oil filler cap
ENGINE OIL FILTER REPLACEMENT

1. Remove:
?? Lower cowlings (Left and right)
Refer to the COWLING REMOVAL AND

2. Warm up the engine for several minutes.
3. Remove:
@Cowling stays (Left and right) @
?? Exhaust pipe
Refer to the “ E N G I N E R E M O V A L -
MUFFLER ASSEMBLY” section in the
CHAPTER 4.
4. Drain the oil.
5. Remove:
0 Oil filler cap
?? Filter cover.@
3-24

ENGINE OIL FILTER REPLACEMENT ADJ @@
PEI
6. Remove:
0 Oil filter @
*Shim @
@Spring @
7. Check:
0 O-ring
Cracks/Damage --f Replace.
8. install:
00il filter (New)
?? Shim
0 Spring
To oil filter cover.
Be sure the O-ring (ij is positioned properly.
9. Install:
0 Oil filter cover
Bolt (Oil Filter Cover):

15 Nm (1.5 m-kg, 11 ft-lb) I
NOTE:
Mesh the oil filter cover projection (0 with
the crankcase slot.
10. Fill:
?? Crankcase
With Oil Filter Replacement:

2.5 L (2.2 Imp qt, 2.64 US qt)
Il. Warm up the engine for a few minutes, then

stop the engine.
12. Observe:
@Oil level
13. Install:
@Center cowlings (Left and right)
3-25

CLUTCH ADJUSTMENT AD J @!iii
I’“s’I
CLUTCH ADJUSTMENT
1. Check:
?? Clutch lever free play :a
2 - 3 mm (0.08 - 0.12 in)
2. Adjust:
?? Clutch lever free play
Adjustment steps:
?? Loosen the locknut @ ,
?? Turn the adjuster @ in or out until the

specified free play is obtained.
Turn in Free play is increased.

Turn out Free play is decreased.
?? Tighten the locknut.
NOTE:
Normally, once the clutch cable length adjuster
(crankcase) is properly set; the only adjustment
required is maintenance of free play at the
clutch cable length adjuster (handlebar lever).
7. Check:
?? Clutch lever free play (a
3-26

AIR FILTER CLEANING/CARBURETOR INSP
JOINT INSPECTION/FUEL LINE INSPECTION AD J @iii
AIR FILTE3 CLEANING
1. Remove:
?? Seat
?? Topcover
Refer to the “COWLING REMOVAL
section.
2. Remove:
?? Air filter case cover @
?? Air filter element
A CAUT’ION:
The engine should never be run without the
air/filter element installed; excessive piston
and/or cylinder wear may result.
3. Clean:
Blow out dust in the element from the
outer surface using compressed air.
4. I nspect :
lair filter element
Damage f Replace.
5. Install:
e Air filter case cover

?? Top cover
?? Seat
CARBURETOR JOINT INSPECTION

I. Remove:
?? Fuel tank
?? Air filter case
2. Inspect :
?? Carburetor joint
Cracks/Damage ~+ Replace.
FUEL LINE INSPECTION

1. Remove:
3-27

CRANKCASE VENTILATION HOSE INSPECTION/
EXHAUST SYSTEM INSPECTION
2. Inspect:
?? Fuel pipes
?? Fuel filter
Contamination/Damage + Replace.
NOTE:
Drain and flush the fuel tank if abrasive damage
to any components is evident.
CRANKCASE VENTILATION HOSE INSPEC-

TION
1. Remove:
0 Seat
?? Top cover

I N STALLATION - REMOVAL” section.
2. Inspect:
?? crankcase ventilation hose @
EXHAUST SYSTEM INSPECTION

1. Remove:
?? Center cowlings (Left and right)

3-28

COOLANT LEVEL INSPECTION/COOLANT REPLACEMENT
3. Tighten:
Nuts (Exhaust Pipe) :

10 Nm (1.0 m-kg, 7.2 ftmlb)
Bolt (Muffler/Rear Footrest) :
20 Nm (2.0 m-kg, 14 ft*lb)
Bolt (Muffler Star) :
(For California only)
20 Nm (2.0 mekg, 14 ft. lb)
COOLANT LEVEL INSPECTION

1. Remove:
0 Seat
@Seat cowling @
2. Inspect:
0 Coolant level
(Reservoir tank @ )
Low level + Add tap water (Soft water).
@Coolant reservoir tank
@“FULL” level
@ “LOW” level
Do not remove the radiator cap when the engine

is hot.
A CAUTION:
Hard water or salt water is harmful to the engine
parts; use boiled or distilled water if you can’t
get soft water.
COOLANT REPLACEMENT
Do not remove the radiator cap when the engine

and radiator are hot. Scalding hot fluid and
steam may be blown out under pressure, which
could cause serious injury. When the engine
has cooled, open the radiator cap by the follow-
ing procedure:
3-29

COOLANT REPLACEMENT
Place a thick rag, like a towel, over the radiator

cap, slowly rotate the cap counterclockwise
to the detent. This procedure allows any residual
pressure to escape. When the hissing sound has
stopped, press down on the cap while turning
counterclockwise and remove it.
1. Remove:
?? ~WW co~\\ng (Left\
-=v~Z7~~ “-La ---z-e _ “--?2++2&~ -+i3xQsW~~
section.
2. Place a drain pan under the drain bolts.
3. Remove:
?? Drain bolt (Outlet pipe) @
?? Drain bolt (Cylinder) @
?? Radiator cap
Drain the coolant.
NOTE:
Remove the drain bolts first, then remove the
radiator cap to prevent the coolant spilling.
4. Tighten:
?? Drain bolt (Cylinder)
?? Drain bolt (Outlet pipe)
Drain Bolt (Cylinder):

7 Nm (0.7 m-kg, 5.1 ft.lb)
Drain Bolt (Outlet Pipe):
I 7 Nm (0.7 mm kg, 5.1 it* lb) I
NOTE:
Replace with new copper gasket.
5. Fill:
?? Cooling system
3-30
COOLANT REPLACEMENT AD J @!!ii
1’““4
Coolant filling steps:

oFill the coolant into the radiator until the
radiator is full.
?? Start the engine (Coolant level decreases.)
‘4 CAUTION:
Always check coolant level, and check for
coolant leakage before starting engine.
?? Add the coolant while engine is running.

?? Stop the engine when coolant level stabilizes.
?? Add the coolant again to specified level @ .
?? Install the radiator cap.
Recommended Coolant:
High Quality Ethylene Glycol
Anti-Freeze Containing
Anti-Corrosion for Aluminum
Engine Inhibitors
Coolant and Water Mixed Ratio:
50%/50%
Total Amount:
1.9 L (1.7 Imp qt, 2.0 US qt)
Reservoir Tank Capacity:
(From Low to Full Level):
0.28 L (0.25 Imp qt, 0.30 US qt)
A CAUTION:
?? Hard water or salt water is harmful to the
engine. You may use distilled water if you
can’t get soft water.
?? Do not mix more than one type of ethlen
glycol antifreeze containing corrosion for

aluminum engine inhabitors.
3-31

FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENT
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Loosen:
?? Adjuster locknut @
2. Adjust:
?? Free play
Turn the adjuster @ until the free play @
is within the specified limits.
Turn in Free play is decreased.

Turn out Free play is increased.
Front Brake Lever Free Play:

2 - 5 mm (0.08 - 0.20 in)
Proper Iever free play is essential to avoid

excessive brake drag.
3. Tighten:
?? Adjuster locknut
REAR BRAKE ADJUSTMENT

1. Loosen:
?? Adjuster locknut @
2. Adjust:
?? Brake pedal height @
Turn the adjuster @ until the brake pedal
position is at the specified height.
?? Rear brake light switch
Refer to the “ R E A R B R A K E L I G H T
SWITCH ADJUSTMENT” section.
After adjusting the brake pedal height, visually

check the adjuster end @ through the hole of
the joint holder @ . The adjuster end must
appear within this hole @ .
3. Lock: \
?? Lock nut @
3-32
BRAKE FLUID INSPECTION/BRAKE PAD INSPECTION
REAR BRAKE LIGHT SWITCH ADJUSTMENT
BRAKE FLUID INSPECTION
I
1. Inspect:
.* *Brake fluid level
Fluid at lower level + Replenish.
@ Front brake fluid lower level
~1
?? Use only designated quality brake fluid to

a avoid poor brake performance.
@Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
*Be sure that water or other contaminants
do not enter master cylinder when refilling.
@Clean up spilled fluid immediately to avoid
erosion of painted surfaces or plastic parts.
@ Rear brake fluid lower level
BRAKE PAD INSPECTION

1. Activate the brake lever or brake pedal.
2. Inspect:
*Wear indicator @
Indicator almost contacts disc+ Replace
pads.
REAR BRAKE LIGHT SWITCH ADJUST-

MENT
1. Loosen:
?? Locknut @

BRAKE HOSE INSPECTION/DRIVE CHAIN SLACK CHECK/
AIR BLEEDING
2. Adjust:
*Rear brake light switch
Hold the switch body @ with your hand so
it does not rotate and turn the adjuster 0.
NOTE:
Proper adjustment is achieved when the brake
light comes on just before the brake begins to take
effect.
BRAKE HOSE INSPECTION

1. Inspect:
??Brake hoses
AIR BLEEDING
Bleed the brake system if:

?? The system has been disassembled.
?? A brake hose has been loosened or removed.

oThe brake fluid is very low.
?? The brake operation is faulty.
A dangerous loss of braking performance may

occur if the brake system is not properly bled.
1. Bleed:
?? Brake system
Air bleeding steps:

a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube@ tightly
to the caliper bleed screw.

14; Front
I$! R e a r
j. Place the other end of the tube into a con-
tainer.
a. Slowly apply the brake lever or pedal sever-
al times.
F. Pull the lever in or push down on the pedal.
Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the lever
or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or
pedal limit has been reached; then release
the lever or pedal.
Bleed Screw:
6 Nm (0.6 me kg, 4.3 ft. lb)
i. Repeat steps (e) to (h) until of the air bub-

bles have been removed from the system.
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have dis-
appeared.
j. Add brake fluid to the level line on the re-

servoir.
NOTE:
Before checking and/or adjusting the chain slack,
rotate the rear wheel through several revolutions.
Check the chain slack several times to find the
point where the chain is the tightest. Check
and/or adjust the chain slack where the rear wheel
is in this “tight chain” position.
1. Place the motorcycle vertically on a leve

place.
2. Measure:
*Drive chain slack @
Out of specification-*Adjust.
Drive Chain Slack:

10 - 20 mm (0.4 - 0.8 in) I
3-35

3. Remove:
*Cotter pin @
4. Loosen:
?? Nut (Rear axle) @
?? Locknut @
5. Adjust:
*Chain slack
Turn the adjuster @ in or out.
Turn in
-____ Chain slack is decreased.
Turn out Chain slack is increased.
NOTE:
There are marks on each side of rear arm and on
each chain puller; use them to check for proper
alignment.
A CAUTION:
Too small chain slack will overload the engine
and other vital parts; keep the slack within the
specified limits.
6. Tighten:
?? Nut (Rear axle)
Nut (Rear Axle):

107 Nm (10.7 m- kg, 77 ft. lb)
7. Tighten:
?? Adjuster
?? Locknut
8. Install:
aCotter pin @ (New)
NOTE:
Do not loosen the axle nut after torque tighten-
ing. If the axle nut groove is not aligned with
the wheel shaft cotter pin hole, align groove to
hole by tightening up on the axle nut.
3-36

DRIVE CHAIN LUBRICATION/STEERING HEAD INSPECTION
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work
against each other. If the chain is not maintained
properly, it will wear out rapidly, therefore, form
the habit of periodically servicing the chain. This
service is especially necessary when riding in
dusty conditions.
This motorcycle has a drive chain with small
rubber O-rings between the chain plates. Steam
cleaning, high-pressure washes, and certain sol-
vents can damage these O-rings. Use only kero-
sene to clean the drive chain. Wipe it dry, and
thoroughly lubricate it with SAE 30 - 5 0 W
motor oil. Do not use any other lubricants on
the drive chain. They may contain solvents that
could damage the O-rings.
Recommended Lubricant:
SAE 30 - 50 Motor Oil or Chain
Lubricants Suitable for “O-ring”
Chains
STEERING HEAD INSPECTION


2. Elevate the front wheel by placing a suitable
stand under the engine.
3. Check:
?? Steering assembly bearings
Grasp the bottom of the front forks and

gently rock the fork assembly back and
forth.
Looseness -+ Adjust the steering head.
4. Remove:
?? Seat
?? Top cover

5. Remove:
?? Handlebars bosses (Left and right)
?? Handlebar crown
Refer to the “STEERING HEAD
HANDLEBAR - REMOVAL” section
in the CHAPTER 7.
3-37

STEERING HEAD INSPECTION AD J m
(INSPI
6. Remove:
?? Lock washer @
0 Ring nut (Upper) 0

*Washer @
7. Remove:
?? Front fork
Refer to the “FRONT FORK - REMO-

VAL” section in the CHAPTER 7
8. Tighten:
?? Ring nuts (Lower and upper)
Ring nuts tightening steps:
NOTE:
Set the Torque Wrench to the Ring Nut
Wrench so that they form a right angle.
?? Install the ring nut (Lower) @ .

.
NOTE:
The tapered side of ring nut must faced down-
ward.
?? Tighten the ring nut @ using the Ring Nut

Wrench.
Ring Nut Wrench:

P/N Y U-33975
Ring Nut @ (Initial Tightening):

52 Nm (5.2 m-kg, 37 ft-lb)
?? Loosen the ring nut @ completely and

retighten it to specification.
Do not over-tightening.
Ring Nut @ (Final Tightening) :

3 Nm (0.3 rn. kg, 2.2 ft. lb)
NOTE:
Recheck the steering head by turning the
steering from lock to lock, after adjusting
steering head.
3-38

STEERING HEAD INSPECTION ADJ m
IINSPI
If steering is binded, loosen the ring nut SO
that there is no free play on bearing.
If steering is loosened, repeat the adjustment
steps.
o install the washer @ .

o Install the ring nut (Upper) @ .
NOTE:
The tapered side of ring nut must face down-
ward.
o Finger tighten the ring nut 0, then align

the slots of both ring nuts. If not aligned,
hold the lower ring nut @ and tighten the
other until they are aligned.
9 Install the lock washer @
NOTE:
Make sure the lock washer tab is placed in the
slots.
?? Install the handle crown and tighten the

steering stem nut to specification.
Nut (Steering Stem) :

110 Nm (11.0 m-kg, 80 ft-lb)
BTighten the pinch bolts to specification.
Pinch Bolt (Handle Crown):

20 Nm (2.0 m-kg, 14 ft-lb)
10. Install:
?? Front fork
?? Handlebars (Left and right)
P
Nut (Front Axle):
/ 58 Nm (5.8 m - kg, 42 ft. lb)
Bolt (Front Fork Pinch):
20 Nm (2.0 me kg, 14 ft. lb)
Bolts (Brake Caliper):
35 Nm (3.5 rn. kg, 25 ft. lb)
Bolts (Handlebar):
20 Nm (2.0 m- kg, 14 ft. lb)
11. Install:
?? Top cover
?? Seat
3-39

FRONT FORK INSPECTION/
REAR SHOCK ABSORBER ADJUSTMENT
FRONT FORK INSPECTION

2. Check:
?? Inner tube
Scratch/Damage + Replace.
?? Oil seal
Excessive oil leakage --f Replace.
3.Hold the motorcycle on upright position
and apply the front brake.
4. Check :
0 Operation
Pump the front fork up and down for
several times.
Unsmooth operation + Repair.
REAR SHOCK ABSORBER ADJUSTMENT

The spring preload of the rear shock absorber
can be adjusted to suit rider’s preference, weight,
and the course conditions.
1. Adjust:
?? Spring preload
Ydjustment steps:
DTO increase preload, adjuster @ is turned
toward the “HI’. To decrease preload, ad-
juster is turned toward the ‘IS”.

TIRE INSPECTION ADJ m
PTI
TIRE INSPECTION
1, Measure:
?? Tire pressure
Out of specification -t Adjust.
Tire inflation pressure should be checked and

adjusted when the temperature of the tire
euqals the ambient air temperature. Tire in-
flation pressure must be adjusted according
to total weight of cargo, rider, passenger, and
accessories (fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
Basic weight:
With oil and full 186 kg (410 lb)
fuel tank (Except for California)
189 kg (417 lb)
(For California)
Maximum load* 156 kg (344 lb)
(Except for California)
153 kg (337 lb)
(For California)
__---
Cold tire pressure Front Rear
~~- - -
200 kPa 230 kPa
Up to 90 kg (2.0 kg/cm’, (2.3 kg/cm*
198 lb) load* 32 psi)
I( 28 psi)
* Load is the total weight of cargo, rider, passen-

ger, and accessories.
2. Inspect:
?? Tire surfaces
Wear/Damage + Replace.
>I
@Tread depth
@Side wall
@Wear indicator
3-41

WHEEL INSPECTION
?? After extensive tests, the tires mentioned below

have been approved by Yamaha motor Co.,
Ltd. for this model. No guarantee for handling
characteristics can be given if tire combinations
other than what is approved are used on this
motorcycle. The front and rear tires should be
of the same manufacture and design.
FRONT:
Manufacture Size Type
Bridgestone 110/70 R17-53H CYO3

I 1
Dunlop 1 lot70 R 17-531-1 K455F
I
REAR:
Bridgestone 140160 R 18-64H CYO4
Dunloo 140/60 R l8-64H K455
?? It is dangerous to ride with a worn-out tire.

When a tire tread begins to show line, replace
the tire immediately.
?? Patching a punctured tube is not recommended.
If it is absolutely necessary to do so, use great

care and replace the tube as soon as possible
with a good quality replacement.
?? Do not attempt to use tubeless tires on a wheel
designed for tube type tires only. Tire failure

and personal injury may result from sudden
deflation.
11
Be sure to install the correct tube when using

tube type tires.
WHEEL INSPECTION
1. Inspect:
?? Aluminum wheels
Damage/Bends + Replace.
Never attempt even small repairs to the
wheel.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
3-42

CABLE INSPECTION/LUBRICATION AD J @fii
mzl
CABLE INSPECTION
1. Inspect:
@Throttle cables
?? Cable sheaths
?? Clutch cable
?? Starter
cable
Check for damage to the cable insulation.
Corrosion/Damage --f Replace.
Obstruction -+ Reroute.
Unsmoothness + Lubricate.
LUBRICATION
Throttle cables/Clutch cable/Starter cable
Cable lubrication steps:

?? Remove the two grip ends that secure
throttle to handlebar.
?? Hold cable end high and apply several drops
of lubricant to cable.
?? Coat metal surface of disassembled throttle
twist grip with suitable all-purpose grease to
minimize friction.
SAE lOW30 Motor Oil
Lever/Pedal
Lubricate pivoting part of each lever and pedal.
SAE lOW30 Motor Oil
Sidestand
Lubricate the pivoting part.
SAE lOW30 Motor Oil
3-43

BATTERY INSPECTION ADJ m
1’““‘1
ELECTRICAL
BATTERY INSPECTION
1. Remove:
0 Seat
Refer to the “COWLING REMOVAL AN
2. Inspect:
Fluid level @ should be between upper 0
and lower @ marks.
Incorrect+ Refill.
Refill with distilles water only; tap water con

tains minerals harmful to a battery.
3. Connect:
?? Breather pipe (Battery) @
Be sure the hose is properly attached ant

routed.
4. Inspect:
*Breather pipe (Battery) @
Obstruction --f Reroute.
Damage + Replace.
When inspecting the battery, be sure the breather

pipe is routed correctly. If the breather pipe
touches the frame or exits in such a way as to
cause battery electrolyte or gas to exit onto the
frame, structural and cosmetic damage to the
motorcycle can occur.
5. Check:
0 Specific gravity:
Less than 1.280 --f Recharge battery.
>
3-44

BATTERY INSPECTION
Replace the battery if:

?? Battery voltage will not rise to a specific value
or bubbles fail to rise even after many hours

of charging.
?? Sulfation of one or more cells occurs, as in-
dicated by the plates turning white, or an ac-
cumulation of material exists in the bottom
of the cell.
?? Specific gravity readings after a long, slow
charge indicate one cell to be lower than the
rest.
*Warpage or buckling of plates or insulators
is evident.
A CAUTION:
Always charge a new battery before using

it to ensure maximum performance.
Battery electrolyte is dangerous; it contains

sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:
mAvoid bodily contact with electrolyte as it
can cause servere burns or permanent eye
injury.
*Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
*SKIN-Flush with water.
*EYES- Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
*Drink large quantities of water or milk
follow with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow
these preventive measures:
?? Charge batteries in a well-ventilated area.
*Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
*DO NOT SMOKE when charging or handl-
ing batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
- .-
3-45

FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT AD J m
mzl
FUSE INSPECTION
The fuse panel is located under the seat.
1. Inspect:
?? Fuses
Defective+ Replace.
Blown fuse (New)+ Inspect circuit.
Install new fuses of proper amperage.
@ Spare fuses
Description Amperage Quantity

Main 30A 1
r Headlight I 10A 1 1
Signal 10A 1
Ignition 10A 1
10A 1
Reserve
30A 1
Blown fuse replacement steps:

*Turn off ignition and the circuit.
. *Install a new fuse of proper amperage.
@Turn on switches to verify operation of elec-
trical device.
@If fuse blows immediately again, check circuit
in question.
Do not use fuses of higher amperage rating

than recommended. Extensive electrical
system damage and fire could result from
substitution of a fuse of improper amperage.
HEADLIGHT BEAM ADJUSTMENT

1. Adjust:
?? Horizontal adjustment:
To adjust the beam to the right, turn the
adjusting screw @ clockwise.
To adjust the beam to the left, turn the
screw @ counterclockwise.
3-46
HEADLIGHT BULB REPLACEMENT AD J @iii
(INS’I
2. Adjust:
@Vertical adjustment:
To raise the beam, turn the adjusting screw
@ clockwise.
To lower the beam, turn the screw @
counterclockwise.
HEADLIGHT BULB REPLACEMENT
1. Remove:
?? Headlight cover @
2. Disconnect:
?? Headlight bulb coupler @
3. Remove:
?? Headlight bulb cover @
4. Remove:
aBulb
Turn the bulb holder counterclockwise to
release bulb.
Keep flammable products or your hands

away from the bulb while it is on, it will be
hot. Do not touch the bulb until it cools
down.
5. Install:
*Bulb (New)
Secure the new bulb with the bulb holder.
Avoid touching glass part of bulb. Also keep

it free from oil otherwise, transparency of
glass, bulb life and illuminous flux will be
adversely affected. If oil gets on bulb, clean
it with a cloth moistened thoroughly with
alcohol or lacquer thinner.
6. Install:
?? Headlight bulb cover
3-47

TAIL/BRAKE BULB REPLACEMENT ADJ m
PEI
7. Connect:
?? Headlight bulb coupler
8. Install:
?? Headlight cover.
TAIL/BRAKE BULB REPLACEMENT

1. Remove:
0 Seat
@Seat cowling
2. Remove:
?? Bulb
socket
Turn the bulb socket approximately 30”
counterclockwise.
3. Remove:
??Defective bulb
4. Install:
?? Bulbsocket
0 Seat cowling
0 Seat
3-48
ENGINE REMOVAL
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE:
It is not necessary to remove the engine in order
to remove the following components:
?? Cylinder head
?? Cylinder
0 Piston
. Clutch
0 Water pump
?? A.C. magneto

UPPER COWLING AND TOP COVER
1. Remove:
0 Upper cowling
0 Seat
?? Top cover
Refer to the “ C O W L I N G R E M O V A L
FUEL TANK
1. Remove:
?? Fuel
tank
Refer to the “ C A R B U R E T O R - RE-
ENGINE OIL
1. Drain:
?? Engine oil
Refer to the “ENGINE OIL REPLACE-

MENT” section in the CHAPTER 3.
COOLANT
1. Drain:
0 Coolant
Refer to the “COOLANT REPLACE-
AIR FILTER CASE AND CARBURETOR

1. Remove:
?? Air filter case
?? Carburetor
Refer to the “ C A R B U R E T O R - RE-

4-1

ENGINE REMOVAL
RADIATOR
1. Disconnect:
?? Hose (Radiator - Inlet) @
?? Hose (Radiator - Outlet) @
2. Disconnect:
?? Fan motor coupler
3. Remove:
?? Radiator assembly
Cover the cylinder head cover and the fender

with rugs to prevent a scratching.
4. Disconnect:
?? Pipes (Left and right)
5. Remove:
?? Pipes (Radiator - Outlet) @
MUFFLER ASSEMBLY
1. Remove:
?? Nuts (Exhaust pipe) @
?? Cowling stays @
?? Bolt (Muffler bracket) @
4-2

ENGINE DISASSEMBLY
MUFFLER ASSEMBLY (For California only)
1. Remove:
?? Nuts (Exhaust pipe) @
?? Cowling stays @
2. Remove:
?? Bolt (Muffler stay)
3. Loosen:
?? Lock nut @
?? Adjuster @
4. Remove:
0 Cover
?? Clips 0
aPulley @
*Cables @
5. Remove:
*Washer @
?? Bracket @
?? Housing @
?? Gasket
(Left side)
?? Shaft arm
4-3
ENGINE REMOVAL
CLUTCH CABLE AND DRIVE CHAIN

1. Remove:
?? Shift arm
?? Crankcase cover (Left)
2. Remove:
?? Clutch cable
3. Straighten:
?? Lock washer tab
4. Remove:
?? Drive sprocket
LEADS
1. Straighten:
0 Clamp
2. Disconnect:
?? Battery leads
NOTE:
Disconnect the negative lead @ first.

ENGINE REMOVAL
3. Disconnect:
?? Lead (Starter motor)
4. Remove:
0 Cover
5. Disconnect:
?? Coupler (Oil level Neutral switch)
?? Coupler (A.C. generator)
?? Coupler (Sidestand switch)
6. Remove:
?? Spark plug leads
ENGINE REMOVAL
1. Remove:
@Cover @
aStarter lever 0
2. Place a suitable stand under the engine.

3. Remove:
i ?? Down tube frames (Left and right) @
I ?? Bolt (Engine-mount) @

ENGINE REMOVAL
4. Remove:
??Bolt (Engine-mounting Lower) @
??Bolt (Engine-mounting Upper) @
?? Collars @
5. Remove:
?? Engine assembly.
From right side.
4-6

ENGINE DISASSEMBLY
ENGINE DISASSEMBLY
CYLINDER HEAD
NOTE:
With the engine mounted, the cylinder head
cover, camshaft and cylinder head can be
maintained by removing the following parts.
?? Seat
?? Top cover
?? Radiator
@Air filter case

?? Carburetor
?? Muffler assembly
?? Down tube frame (Right)
1. Remove:
@Cylinder head cover @
?? Gasket (Cylinder head cover)
*Spark plugs @
2. Remove:
@Generator cover @
?? Dowel pins
3. Turn:
?? Crankshaft
Counterclockwise
4. Align:
?? “T” mark @
?? Crankcase end @
NOTE:
When #1 piston is at TDC on compression
stroke.

ENGINE DISASSEMBLY
5. Remove:
?? Cam chain tensioner @
?? Gasket (Cam chain tensioner)
6. Remove:
?? Union bolts @
?? Oil delivery pipe @
7. Remove:
?? Cam chain guide (Upper) @
?? Cam chain guide (Exhaust side) @
NOTE:
?? Select either of the two procedures explained
in this manual, as follows:
??Procedure 1.
For engine service except cylinder head dis-
assembly.
-+ Disconnect the cam chain.
The pistons and cylinder can be removed
without removing the camshafts.
??Procedure 2.
For engine service including cylinder head
disassembly.
--f Remove the cam caps and camshafts.
The camshafts can be removed without dis-
connecting the cam chain.
4-8

ENGINE DISASSEMBLY ) ENG lq-1
Procedure 1.
1. Disconnect:
?? Cam chain
Use the Cam Chain Cutter @ .
Cam Chain Cutter:

P/N YM-01112
2. Remove:
?? Rubbers (Camshaft cap) @
3. Remove:
?? Nuts (Cylinder head)
Use the Hexagon Wrench 6 mm (0.24 in)@.

4. Remove:
?? Cylinder head
??Gasket (Cylinder head)

o Dowel pins
5. Go to “CYLINDER AND PISTON”.
Procedure 2.
1. Remove:
?? Camshaft caps
?? Dowel pins
NOTE:
Remove the camshaft caps in a crisscross pattern
from outermost to inner caps.
A CAUTIOM:
Do not rotate the camshaft or valve damage may
occur.
2. Remove:
?? Camshafts
Fasten safety wire @ to the cam chain to pre-

vent it from falling into the crankcase.
4-9

ENGINE DISASSEMBLY
3. Remove:
Use the Hexagon Wrench 6 mm (0.24 in)@.
NOTE:
?? Loosen the nuts in their proper loosening
sequence.
?? Follow numerical order shown in photo.
Start by loosening each nut l/2 turn until
all are loose.
4. Remove:
?? Cylinder head
NOTE:
Remove the cylinder head as a whole to prevent
the valve lifters and adjusting pads from falling
into the crankcase.
5. Remove:
aGasket (Cylinder head) @
@Dowel pins @
CYLINDER AND PISTON
NOTE:
With the engine mounted, the cylinder and piston
can be maintained by removing the following
parts.

?? Seat
*Top cover
?? Radiator
?? Air filter case

?? Carburetor
?? Muffler assembly
?? Down tube frame (Right)
?? Cylinder head
4-10

ENGINE DISASSEMBLY
1. Remove:
0 Water pipe @
0 O-rings
?? Cylinder
2. Remove:
?? Gasket (Cylinder) @
?? Dowel pins @
3. Mark:
0 Pistons
With the piston number designations as
shown.
4. Remove:
?? Circlips (Piston pin) @
NOTE:
Before removing the piston pin circlip, cover the
crankcase with a clean rag to prevent the circlip
from falling into the crankcase cavity.
5. Remove:
?? Piston pins 0
0 Pistons @
NOTE:
Before removing the piston pin, deburr the clip
grooved and pin hole area. If the piston pin
groove is deburred and piston pin is still difficult
to remove, use the Piston Pin Puller 0.
Piston Pin Puller:

P/N YU-01304
Do not use a hammer to drive the piston pin

out.
4-11

ENGINE DISASSEMBLY
STARTER CLUTCH
NOTE:
With the engine mounted, the starter clutch can
be maintained by removing the following parts.
?? Starter clutch cover
1. Remove:
*Starter clutch cover @
?? Gasket (Starter clutch cover)
?? Dowel pens.
2. Remove:
?? Bolt (Starter clutch) @
?? Washer
3. Attach:
?? Heavy Duty Puller @
Heavy Duty Puller:

Y U-33270
4. Remove:
?? Starter clutch @
5. Remove:
?? woodruff key @
?? Starter clutch gear @
?? Idle gear @I
?? Idle gear @
4-12

ENGINE DISASSEMBLY
CLUTCH
NOTE:
With the engine mounted, the starter clutch can
?? Crankcase cover (Right)
1. Remove:
?? Crankcase cover (Right) @
?? Gasket (Crankcase cover)
?? Dowel pins
NOTE:
Working in a crisscross pattern, loosen bolts l/4
turn each. Remove them after all are loosened.
2. Remove:
?? Bolts (Clutch spring) @
*Clutch springs @
?? Pressure plate @
?? Friction plates
?? Clutch plates
NOTE:
Loosen the bolts in a crisscross pattern.
3. Remove:
?? Push rod #l @
aBall @
?? Push rod #2 @
4. Straighten the lock washer tabs.

5. Loosen:
@Nut (Clutch boss) @
Use the Universal Clutch Holder 0.
Universal Clutch Holder:

P/N Y M-91 042
NOTE:
Hold the clutch boss loosen the nut by Universal
Clutch Holder 0.

ENGINE DISASSEMBLY
6. Remove:
.Nut (Clutch boss) @
?? Lock washer @
@Clutch boss @
thrust washer @
7. Remove:
?? Spacer @
?? Bearing @
NOTE:
Install the 5 mm (0.2 in) screw @ on the spacer
@ then remove the spacer with pulling out
screw.
8. Remove:
aClutch housing @
9. Remove:
?? Thrust washer @
*Collar @
A.C. MAGNETO
NOTE:
With the engine mounted, the A.C. Magneto can
?? Lower cowling ( Left)
?? Generator cover
4-14

ENGINE DISASSEMBLY
1. Remove:
@Bolt (Magneto) @
?? Washer
NOTE:
Hold the magneto to loosen the nut by the
Universal Rotor Holder 0.
LFI Universal Rotor Holder:

P/N YU-01235 I
2. Attach:
0 Rotor puller @
P/N YM-01080
3. Remove:
*Magneto @
4. Remove:
?? Starter coil assembly @
?? Pickup coil @
@Woodruff key @
WATER PUMP
NOTE:
With the engine mounted, the water pump can
0 Seat
?? Top cover
?? Lower cowling ( Right)
aShift arm
0 Water pipe
0 Water pump cover
4-15

ENGINE DISASSEMBLY
OIL PUMP AND SHIFT SHAFT
NOTE:
With the engine mounted, the oil pump and
shift shaft can be maintained by removing the
following parts.
?? Clutch housing
1. Remove:
*Oil pump assembly @
2. Remove:
*Gasket (Oil pump assembly) @
?? Dowel pin @
4-16

ENGINE DISASSEMBLY (ENG lb1
3. Remove:
?? Shift shaft assembly @
OIL PAN AND OIL STRAINER
NOTE:
With the engine mounted, the oil pan and oil
strainer can be maintained by removing the
following parts.
??Muffler assembly
scowling stay
1. Disconnect:
?? 0il level switch lead @
?? Neutral switch lead @
2. Remove:
0 Oil filter cover @
?? Oil filter
3. Remove:
@Drain p l u g @
?? 0il level switch @
?? Oil pan @
?? Gasket (Oil pan)
?? Dowel pins
4-17

ENGINE DISASSEMBLY
4. Remove:
0 Oil strainer cover 0
?? Relief valve @
5. Remove:
?? Oil strainer assembly @
STARTER MOTOR
NOTE:
With the engine mounted, the starter motor,
can be maintained by removing the following
parts.
0 Seat
?? Top cover
?? Fuel tank
1. Remove:
?? Starter motor 0
?? crankcase ventilation hose @
CRANKCASE DlSASSErVlBLY
1. Remove:
0 Oil seal stopper @
4-18

ENGINE DISASSEMBLY
3. Remove:
JA
?? Bolts (Crankcase)
NOTE:
G ?? Remove the bolts starting with the highest
numbered one.
*The e m b o s s e d n u m b e r s i n t h e c r a n k c a s e
designate the crankcase tightening sequence.
4. Place the engine upside down.

5. Remove:
?? Crankcase (Lower)
Use a soft hammer.
?? Upper case
[BIL ower case
TRANSMISSION, SHIFTER AND SHIFT CAM

1. Remove:
?? Transmission assembly @
?? Dowel pins
2. Remove:
@Stopper lever 0
?? Stopper plate (Shift cam) @
3. Remove:
?? Guide bars @
@Shift f o r k #l @
*Shift fork #2 @
aShift f o r k #3 @

ENGINE DISASSEMBLY
4. Remove:
?? Shift cam
CRANKSHAFT
1. Remove:
?? Crankshaft assembly
2. Remove:
?? Main journal bearing
NOTE:
Identify each main journal bearing position
very carefully so that it can be reinstalled in
its original place.
4. Remove:
?? Neutral switch
4-20

ENGINE DISASSEMBLY
5. Remove:
?? Breather hose
@Oil baffle plate
VALVE PAD AND VALVE
NOTE:
With the engine mounted, the valve pad and
valve can be maintained by removing the
following parts.
@Center cowlings (Left and right)

?? Fuel tank
?? Carburetor
?? Radiator
@Generator cover
eCam chain tensioner

@Cylinder head
1. Remove:
0 Lifters 0
?? Valve pads
NOTE:
Identify each lifter and pad position very care-
fuly so that it can be reinstalled in its original
place.
--
@ Lifters
@ Valve pads
4-21

ENGINE DISASSEMBLY
2. Check:
0 Valve sealing
Leakage at valve seat + inspect the valve
face, valve seat and valve seat width.
Refer to the “INSPECTION AND REPAIR
- VALVE SEAT” section.
NOTE:
Before removing the internal parts (valve, valve
spring, spring seat, etc.) of the cylinder head, the
valve sealing should be checked.
Valve seal checking steps:

?? Supply a clean solvent @ into the intake
and exhaust ports.
?? Check the valve sealing. There should be no
leakage at the valve seats 0.
3. Attach:
0 Valve spring compressor @
?? Attachment @
Valve Spring Compressor:

P/N YM-04019
Attachment:
P/N Y M-04108
@Valve retainers
4. Remove:
0 Valve retainers @
0 Valve spring seat @
*Oil seal @I
0 Valve spring @
*Valve @
*Valve spring seat @
NOTE:
Identify each part position very carefuly so that
it can be reinstalled in its original place.

ENGINE DISASSEMBLY
CONNECTING ROD
1. Remove:
?? connecting rod @
?? Connecting rod bearing
INNER ROTOR (OIL PUMP)

1. Remove:
?? Pump housing
2. Remove:
*Outer rotor @
@Pin @
0 Inner rotor 0
??Washer @
0 Pump cover @
?? Pump shaft @
4-23

CYLINDER HEAD
1. Eliminate:
?? Carbon deposit
(from combustion chamber)

Use rounded scraper.
NOTE:
Do not use a sharp instrument and avoid damag-
- - ing or scratching:
?? Spark plug threads
?? Va Ive seat
2. Inspect:
?? Cylinder head
Scratches/Damage + Replace.
3. Measure:
0 Warpage
Out of specification -+ Resurface.
Cylinder Head Warpage:

Less than 0.03 mm (0.0012 in)
4. Resurface:
?? Cylinder head
Resurfacement steps:
Place a 400 - 600 grit wet sandpaper on the
surface plate, and resurface the head using a
figure-eight sanding pattern.
NOTE:
Rotate the head several times to avoid remov-
ing too much material from one side.
I I
4-24

VALVE
1. Inspect:
0 Valve face
@Stem end
Wear/Pitting + Reface.
Face Width @ :
1.6 - 2.4 mm (0.0630 - 0.0945 in)
Seat Width @ :
0.9 - 1.1 mm (0.0354 - 0.0433 in)
< Limit >
1.6 mm (0.063 in)
Margin Thickness @ :
0.6 - 0.8 mm (0.0236 - 0.0315 in)
< Limit >
0.4 mm (0.0157 in)
2. Measure:
0 Valve stem clearance
Valve stem clearance =

Valve guide inside diameter @ -
Valve stem diameter @
Out of specification + Replace either valve

and/or guide.
Use a Micrometer and Bore Gauge @
Valve Stem Clearance Maximum
0.010 - 0.037 mm 0.08 mm

Intake
(0.0004 - 0.0015 in) (0.0031 in)
Exhaust 0.025 - 0.052 mm 0.1 mm

(0.001 - 0.002 in) (0.0039 in)
3. Inspect:
?? Valve stem end
Mushroom shape/Larger diameter than rest

of stem + Replace valve, valve guide, and
oil seal.
4-25

4. Measure:
0 Valve stem runout
Maximum Runout:
0.02 mm (0.0008 in)
VALVE GUIDE
NOTE:
?? Always replace the valve guide if the valve is
replaced.
?? Always replace the oil seal if the valve is
removed.
1, Inspect:
?? Valve guide
Wear/Oil leakage into cylinder --f Replace.

2. Remove:
?? Valve guide
Use the Valve Guide Remover 0.
Valve Guide Remover (4.5 mm):

P/N YM-04116
302-019
3. Install:
?? Valve guide (New)
Use the Valve Guide Installer @ with the

valve Guide Remover @ .
p Valve Guide Installer:

P/N YM-04117
Valve Guide Remover (4.5 mm):
302-020
P/N YM-04116
4. Bore valve guide @ to obtain proper valve

stem clearance.
Use the Valve Guide Reamer (4.5 mm) @ .
Valve Guide Reamer (4.5 mm):

P/N YM-04118
NOTE:
Reface the valve seat after installing the valve
301013 guide.
4-26

VALVE SEAT
1. Clean:
?? Valve face
?? Valve seat
Remove carbon deposit.
2. Inspect:
?? Valve seat
Pitting/Wear + Reface valve seat.
3. Measure:
?? Valve seat width @
Out of specification + Reface valve seat.
Valve Seat Width
Intake 0.9 - 1.1 m m (0.035 - 0.043 in)

Exhaust 0.9 - 1.1 m m (0.035 - 0.043 in)
302 027
Valve seat width measurement steps:

?? Apply the Mechanic’s bluing dye (Dykem)
@ to the valve face.
?? install the valve into the cylinder head.
?? Press the valve through the valve guide and

onto the valve seat to make a clean pattern.
?? Measure the valve seat width. Whether the
valve seat and valve face made contact,
302 017
bluing will have been removed.
elf the valve seat width is too wide, too
narrow, or seat has not centered. The valve
seat must be refaced.
4. Reface:
?? Valve seat
Use 20”, 45” and 60” Valve Seat Cutter.
Valve Seat Cutter Set (ij :

P/N YM-91043
4-27

A CAU’IIQN:
Remove just enough material to achieve satis-
factory seat.
When twisting cutter, keep and even downward
pressure to prevent chatter marks.
Cut sections as follows I

I Section I Cutter I
I
B 45”
C 60” ---I
Valve seat refacing steps:

d Valve face indicates that valve seat is
centered on valve face but is too wide.
4 V aI ve seat is in the middle of the valve

face but too narrow.
down near the bottom edge of the valve

face.
increase its width.
4-28
5. Lap:
0 Valve face
0 Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
Valve lapping steps:

?? Apply a coarse lapping compound @ to the
valve face.
A CAUTION:
Be sure no compound enteres the gap between
the valve stem and guide.
302 017
?? Apply a molybdnum disulfide oil to the
valve stem.
?? Install the valve into the cylinder head.
?? Turn the valve until the valve face and

valve seat are evenly polished, then clean
off all compound.
NOTE:
1
1% 302 024
To obtain the best lapping result, lightly tap
the valve seat while rotating the valve back
and forth between your hand.
?? Apply a fine lapping compound to the valve

face and repeat the above steps.
NOTE:
Be sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
?? Apply the Mechanic’s bluing dye (Dykem)

@ to the valve face.
?? Install the valve into the cylinder head.
302 017
4-29

?? Press the valve through the valve guide and

onto the valve seat to make a clear pattern.
@Measure the valve seat width @ again. If
the valve seat width is out of specification,
reface and lap the valve seat.
VALVE SPRING
1. Measure:
?? Valve spring free length @
Out of specification --f Replace.
Valve Spring Free Length:

41.94 mm (1.65 in)
302 “05
2. Measure:
?? Valve spring installed force @
@ Installed length
Valve Spring Installed Force:
302 006 0
I 37.5 mm (1.48 in)

14.2 - 16.4 kg
(31.3 - 36.2 lb)
3. Measure:
*Spring Tilt @
Spring Tilt:
Less than 1.8 mm (0.0709 in) I

VALVE LIFTER
1. I nspect:
0 Valve lifters
Scratches/Damage + Replace both lifters
and camshaft case.
CAMSHAFT, CAM CHAIN, AND CAM

SPROCKET
Camshaft
1. I nspect :
aCam lobes
Pitting/Scratches/Blue discoloration +
Replace.
2. Measure:
*Cam lobes
Use the Micrometer.
Cam Lobe Cam Lobe

(iJ (Limit) @ (Limit)
32.51 mm 25.005 mm
Intake
(1.2799 in) (0.9844 in)
32.21 mm 24.96 mm
Exhaust
(1.2681 in) (0.9827 in)
3. Measure:
?? Camshaft runout
Use the Micrometer.

Camshaft Runout Limit:

0.03 mm (0.0012 in)
Camshaft/Cap Clearance Measurement

1. Install:
?? Camshaft
2. Position:
?? Strip of Plastigage@ @
Onto the camshaft.
Plastigage@ :
P/N W-33210
4-31

3. Install:
?? Dowel pins
?? Camshaft caps
4. Tighten:
*‘
t ?? camshaft cap bolts
Bolts (Camshaft Cap) :

10 Nm (1.0 m-kg, 7.2 ftslb)
NOTE:
?? Tighten the camshaft caps in a crisscross
pattern from innermost to outer caps.
?? Do not turn the camshaft when measuring
clearance with the Plastigage@.
5. Remove:
?? Camshaft caps
6. Measure:
?? Width of Plastigage@ @
Out of specification + Follow step 7.
>
7. Measure:
?? Camshaft outside diameter @
Use a micrometer.
Out of specification -+ Replace the cam-
shaft.
Within specification -+ Replace the cam-
shaft case.
Camshaft Outside Diameter:

Standard: 22.967 - 22.980 mm
(0.9042 - 0.9047 in)
Cam Cap Inside Diameter:
Standard: 23.000 - 23.021 mm
(0.9056 - 0.9063 in)
4-32

Cam Chain
1. Inspect:
*Cam chain
Chain stretch/Cracks --f Replace.
Cam Sprockets
1. Inspect:
*Cam sprockets
Cam Chain Guide

1. I nspect:
?? Cam chain guide (Exhaust side) @
?? Cam chain guide (intake side) @
Wear + Replace.
Cam Chain Tensioner

1. Check:
@One-way cam 0 operation
Unsmooth operation + Replace.
2. Inspect:
@AlI parts
Damage/Wear -+ Replace.
@ Collar
as er
% :dhp’ug @ Tensioner body
@ Springs @ Tensioner rod
CYLINDER AND PISTON

1. Inspect:
?? cylinder and Piston walls
Vertical scratches --f Rebore or Replace
cylinder and piston.
2. Measure:
?? Piston-to-cylinder clearance
4-33

Piston-to-cylinder clearance measurement

steps:
First step:
D Measure the cylinder bore “C” with a
Cylinder Bore Gauge.
NOTE:
Measure the-cylinder bore “C” in parallel to
and at right angles to the crankshaft. Then,
find the average of the measurements.
Standard Wear Limit

-.
Cylinder 56.000 - 56.005 mm 56.05 mm
bore “C” (2.2047 - 2.2049 in) (2.2067 in)
C = Maximum D
T = (Maximum D, or D, ) -
(Maximum D, or D6 )
R = (Maximum D,, D, or D,) -
(Minimum D, , D4 or D,)
?? If out of specification, rebore or replace
cylinder, and replace piston and piston rings
as a set.
2nd step:
r Measure the piston skirt diameter “P” with
a micrometer.
@ 5.0 mm (0.2 in) from the piston bottom edge.
Piston Size P
D If out of specification, replace piston and

piston rings as a set.
3rd step:
DCalculate the piston-to-cylinder clearance
with following formula:
Piston-to-cylinder Clearance =
Cylinder bore “C” -
Piston skirt diameter “P”
4-34

?? If out of specification, rebore or replace

cylinder, and replace piston and piston rings
a
as a set.
Piston-to-cylinder Clearance:
I Limit: 0.15 mm (0.006 in)
PISTON RING AND PISTON PIN

Piston Ring
1. Measure:
?? Side clearance
Use the Feeler Gauge 0.
Out of specification + Replace the piston
and/or rings.
NOTE:
307.or6
Decarbon the piston ring grooves and rings
before measuring the side clearance.
Side Clearance:
Standard Limit
I Top ring
0.03 - 0.07 mm
(0.0012 - 0.0028 in)
0.10 mm
(0.004 in)
I 2nd ring
0.02 - 0.06 mm
(0.0008 - 0.0024 in)
0.10 mm
(0.004 in)
2. Position:
0 Piston ring
Into cylinder.
20mm
(0.8in) NOTE:
Insert the ring into the cylinder, and push it
approximately 20 mm (0.8 in) into the cylinder.
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
3. Measure:
?? End gap
4-35
End Gap (Installed) :

Standard
T o p ring 0.15 -0.30 mm
(0.0059 - 0.0118 in)
2nd ring 0.15 -0.30 mm
(0.0059 - 0.0118 in)
Oil control 0.2 - 0.8 mm
(Rails) (0.0079 - 0.0315 in)
Piston Ring Oversize

stop and 2nd piston ring
Oversize top and middle ring size is stamped
on the top of ring.
I Oversize 2 0.50 mm (0.0197 in)
*Oil control ring

Expander spacer of bottom ring (oil control
ring) is color-coded to identify sizes.
I Size Color I
I Oversize 2 Red
I
Piston Pin
1. Lubricate:
?? Piston pin (Lightly)
SAE lOW30 Motor Oil
2. Install:
?? Piston pin
Into the small end of connecting rod.
3. Check:
@Free play
Free play -j Inspect the connecting rod for
wear.
Wear --f Inspect the connecting rod and
piston pin.
4. Position:
?? Piston pin
Into the piston.
4-36
5. Check:
?? Free play
When the pin is in place in the piston.
Free play + Replace the piston pin and/or
piston.
CRANKSHAFT AND CONNECTING ROD

Crankshaft
1. Measure:
??Runout
Use the V-Blocks and Dial Gauge.

Out of specification --t Replace.
308 005 I
la Runout Limit:
0.03 mm (0.0012 in) I
2. Inspect:
??Crankshaft journal surfaces
Main Journal Oil Clearance
1. Clean all parts.

2. Position:
?? Crankshaft journal surfaces
Place on a bench in an upside down posi-

tion.
3. Install:
?? Main journal bearings
Into the upper crankcase.

acrankshaft
4. Attach:
0 Plastigage@ @
Onto the crankshaft journal surface.
4-37

5. Install:
*Bearings
Into the lower crankcase.
?? Crankcase (Lower)
6. Tighten:
.Bolts
Tighten to full torque in torque sequence cast

on the crankcase.
1
Bolt @ - @ :
24 Nm (2.4 m-kg, 17 ft*lb)
Bolt @ - @ :
I 12 Nm (1.2 m-kg, 8.7 ftalb)
7. Remove:
.Bolts
Reverse assembly procedure.
?? crankcase (Lower)
Use care in removing.
8. Measure:
?? Plastigage width @
Out of specification --f Replace the bearings;

replace the crankshaft if necessary.
>]
Connecting Rod Bearings

1. I nspect:
?? Connecting rod bearings
Burns/Flaking/Roughness/Scratches +
Replace.
4-38
Connecting Rod Oil Clearance
1. Clean all parts thoroughly.
2. Install:
?? Connecting rod bearings
Into the connecting rod and cap.

3. Attach:
0 Plastigage@ @
Onto the crank pin.
4. Install:
?? Connecting rod
?? Connecting rod cap
NOTE:
?? Be sure the “Y” marks @ on the connecting
rods face toward left crankshaft end .
?? Be sure the letters on both components align
to form a perfect character.
5. Lubricate:
?? Bolt threads (Connecting rod)
?? Nut seats (Connecting rod)
Molybdenum Disulfide Grease
6. Tighten:
?? Nuts (Connecting rod cap)
Do not turn the connecting rod until the

clearance measurement has been completed.
Tighten to full torque specification without

pausing. Apply continuous torque between
1.2 and 2.3 m-kg. Once you reach 1.2 m-kg
DO NOT STOP TIGHTENING until final torque
is reached. If tightening is interrupted between
1.2 and 2.3 m-kg, loosen nut to less than
1.2 m-kg, and start again.
I Nuts (Connecting Rod) :

23 Nm (2.3 m-kg, 17 ft-lb) I
4-39

7. Remove:
?? connecting rod cap
Use care in removing.
8. Measure:
?? Width of Plastigage@ @
Out of specification + Replace the bearings
and/or replace the crankshaft if necessary.
Connecting Rod Oil Clearance:

0.043 - 0.0066 mm
(0.0017 - 0.0026 in)
Crankshaft Main Journal and Connecting Rod

J2 J4 J6 P2 P4
Bearing Selection
?? Numbers used to indicate crankshaft journal
sizes are stamped on the LH crankweb. The
first six (6) are main journal bearing numbers,
starting with the left journal. The four (4)
connecting rod bearing numbers follow in the
same sequence.
?? The upper crankcase half is numbered Jl, J2,

J3, J4, J5 and J6 on the rear right bosse as
shown.
?? The numbers are stamped in ink on the rod

cap@.
BEARING COLOR CODE

No. 1 Blue
No. 2 Black
No. 3 Brown
No. 4 Green
*No.5 Yellow
3c No. 5 applies only to the main journal bear-

ing selection.
4-40
Example 1: Selection of the main journal

bearings:
@If the crankcase Jl and crankshaft Jl sizes
r
are No. 4 and No. 1, respectively, the bearing
size No. is:
Bearing Size No. =

Crankcase No. - Crankshaft No. =
4 - 1 = 3 (Brown)
I BEARING COLOR CODE

No. 1 Blue 1
Example 2: Selection of the connecting rod

bearing:
?? If the connecting rod Pl and crankshaft Pl
sizes are No. 5 and No. 1, respectively, the
bearing size No. is:
Bearing Size No. =

Connecting rod No. - Crankshaft No. =
5 - 1 = 4 (Green)
BEARING COLOR CODE
01 L PUMP
1. Measure:
?? Tip clearance “A”
Between the inner rotor @ and the outer

rotor@ .
@Side clearance “B”
Between the outer rotor @ and the pump
housing @ .
Use the Filler Gauge and Straight Edge.
Out of specification + R e p l a c e t h e o i l
pump assembly.
4-41

2. Lubricate:
0 inner rotors
0 Outer rotors
0 Oil seal
?? Pump shaft
SAE lOW30 Motor Oil
3. Install:
Reverse removal procedure.
Alighn the pins in the pump shaft and the

groove on the inner rotors dualing assembly.
4. Check:
0 Oil pump operation
With a finger.
Unsmooth operation + Repeat step 2. or
replace.
PRIMARY DRIVE
1. Inspect:
?? Primary drive gear (Crank shaft) @
?? Primary driven gear @
Wear/Damage --f Replace both gears.

Excessive noises during operation -+
Replace both gears.
4-42

STARTER CLUTCH
1. Check:
?? Roller operation
Push the roller to arrow direction.

Unsmooth operation + Replace starter
clutch.
2. Inspect:
*Starter idle gear teeth @
@Starter drive gear teeth @
Burrs/Chips/Roughness/Wear -+ Replace.
3. Inspect:
?? Contacting surfaces
Pitting/Wear/Damage -+ Replace.
4. Check :
?? Starter clutch operation
Clutch operation checking steps:

?? Install the starter clutch gear to the starter
clutch, and hold the starter clutch.
?? When turning the starter clutch gear clock-
wise the starter clutch and the wheel gear

should be engaged.
If not, the starter clutch is faulty. Replace
it.
?? When turning the starter clutch gear counter-
clockwise, the starter clutch gear should

turn freely.
If not, the starter clutch is faulty. Replace it.
4-43

INSPECTION AND REPAIR pqq
CLUTCH
Clutch Housing
1 . Inspect :
?? Dogs on the housing
Cracks/Wear/Damage --f Deburr or replace.

?? Clutch housing bearing
Chafing/Wear/Damage + Replace.
NOTE:
Wear on the friction plate dogs of the clutch
housing will cause an erratic operation.
Clutch Boss
1 . Inspect :
?? Clutch boss splines @
Scoring/Wear/Damage + Replace clutch

boss assembly.
NOTE:
Scoring on the clutch plate splines will cause
erratic operation.
Friction Plates
1. Inspect:
?? Friction plate
Damage/Wear -+ Replace the friction plates
as a set.
2. Measure:
?? Friction plate thickness
Measure at all four points.
4’1 )OL Out of specification + Replace the friction
plates as a set.
2.8 mm (0.11 in)
Clutch Plates
1. Measure:
?? Clutch plate warpage
Use the surface plate and Feeler Gauge @ .

0.1 mm (0.004 in)
4-44

2. Inspect:
?? Pressure plate
Damage + Replace.
Push Rod
1. I nspect :
@Push r o d 1 @
.Bofl @
@Push rod 2 @
Wear/Cracks/Damage -+ Replace.
Push Lever Assembly and Boll Screw Housing

1. I nspect :
?? Push lever assembly
Unsmooth + Replace.
2. Measure:
?? Push rod runout
Use the V-Blocks and Dial Gauge.
Clutch Spring
1. Measure:
?? Clutch spring free length
Out of specification + Replace the springs

as a set.
Clutch Spring Minimum Free Length:

29.0 mm (1.14 in)

TRANSMISSION
Shift Fork
1. Inspect:
?? Shift fork cam follower @
?? Shift fork paw1 @

Wear/Chafing/Bends/Damage + Replace.
2. Check:
?? Shift fork movement
On its guide bar @ .

Unsmooth operation + Replace the fork
and/guide bar.
Shift Cam
1. Inspect:
?? Shift cam grooves
Wear/Damage/Scratches + Replace.
?? Shift cam segment
Damage/Wear + Replace.
?? Shift cam bearing
Pitting/Damage + Replace.
Main and Drive Axles

1. Measure:
?? Axle runout @
Use the centering device and Dial Gauge@.

Runout Limit: 0.08 mm (0.0031 in)
Gears
1. Inspect:
?? Gears
2. Check:
?? Gear movement
Unsmooth operation + Replace.

3. Inspect:
?? Mating dogs
Cracks/Wear/Damage + Replace.
Shift Shaft Assembly
1. Inspect:
?? Shift shaft
Bends/Wear/Damage -f Replace.
0 Spring
Damage + Replace.
4-46

INSPECTION AND REPAIR -1
RELIEF VALVE AND PIPE
1. Check:
?? Relief valve body @
?? Cover 0
*Spring @
?? O-ring @
2. Check:
?? Oii pipe 0
Damage + Replace.
Comtamination + Wash and blow out
the passage.
3. Check:
?? Water pipe @
?? Water jacket joint @
?? O-rings @
Damage --f Replace.
CRANKCASE
1. Inspect:
?? Case halves
?? Bearing seat
?? Fitting
Damage + Replace
BEARING AND OIL SEAL

1. Inspect:
?? Bearings
Clean and lubricate, then rotate inner race

with finger.
Roughness + Replace the bearing (see Re-
moval).
2. Inspect:
@Oil seals
Damage/Wear + Replace the (see Removal).
4-47

YAMAHA EXHAUST VARIABLE VAiVE
(For California Only)
1. I nspect :
?? Shaft arm
Wear/Cracks/Damage -+ Replace.
2. Inspect:
.Bush @
Wear -+ Replace.
4-48

ENGINE ASSEMBLY AND ADJUSTMENT
ENGINE ASSEMBLY AND
ADJUSTMENT
INNER ROTOR (OIL PUMP)
1. Install:
?? Pump shaft @
0 Pump cover @
@Washer @
0 inner rotor @
*Pin @
?? Outer rotor @
NOTE:
Insert the inner rotor @ into the outer rotor 0.
Then with the pump shaft dowel pin @ in the
inner rotor slit.
2. Install:
?? Pump housing
CONNECTING ROD
1. Clean:
?? Crankshaft
?? Connecting rods
a
-41 M
2. Install:
*Connecting rod bearings
Into the connecting rod and cap.
3. Lubricate:
@Connecting rod bolt threads
?? Connecting rod nuts
Molybdenum Disulfide Oil
4. Apply engine oil to the crankshaft pins.
4-49

CRANKSHAFT
@Crankshaft
g ii1 se;1
ain ournal bearing
@Connecting rod assembly
@Connecting rod bolt
@Connecting rod bearing
@Nut

5. Install:
@Connecting rods
aconnecting rod caps
NOTE:
@The stamped “Y” mark on the connecting rods
@ should face towards the left side of the
crankcase.
?? Be sure the letter on both components align to
form a perfect character.
6. Install:
@Connecting rod bolts
Align the bolt head and connecting rod cap.
7. Tighten :
?? Connecting rod nuts
Tighten to full torque specification without

pausing. Apply continuous torque between
1.2 and 2.3 m-kg. Once you reach 1.2 m-kg.
DO NOT STOP TIGHTENING until final torque
is reached. If the tightening is interrupted
between 1.2 and 2.3 m*kg, loosen the nut to
less than 1.2 m-kg and start again.
bA 23 Nm (2.3 m-kg, 17 ftlb)
1 VALVE PAD AND VALVE
Deburr any deformed valve stem end. Use an oil

, stone to smooth the stem end.
~Deburr
@Valve stem
1. Eliminate:
?? Carbon deposit
From the combustion chamber.

Use a rounded scraper.
NOTE:
Do not use a sharp instrument and avoid damag-
ing or scratching:
@Spark plug threads
??Va Ive seat
?? Cylinder head
4-51
1 ENG I%1
2. Install:
0 Valve spring seat @
?? Oil seal @
3. Install:
0 Valve
NOTE:
Apply molybdenum disulfide oil.
4. Install:
0 Valve spring @
NOTE:
Install springs with wider-gapped coils facing
upwards, as shown.
@ Larger pitch
@Smaller pitch
5. Attach:
??Valve spring compressor @
?? Attachment @
6. Install:
aValve retainers @
7. Settle the valve retainer by lightly patting
the valve seat with a piece of wood @ in
between.
NOTE:
Do not hit so much as to damage the valve.
4-52
8. Install:
@Valve pads @
NOTE:
Apply molybdnum disulfide oil.
9. Install:
0 Lifters @
CRANKSHAFT
1. Install:
?? Oil baffle plate
?? Breather hose
Oil Baffle Plate Bolts:

10 Nm (1.0 m-kg, 7.2 ft.lb)
2. Install:
?? Neutral switch assembly @
3. Install:
?? Cam chain guide (Intake side) @
?? O-ring @
Bolts (Chain Guide):

10 Nm (1.0 m-kg, 7.2 ftalb)

CRANKCASE
@Crankcase assembly @ 8 mm bolt
@Oil level window @ O-ring
@Crankcase ventilation hose 0 8 mm bolt
(436 mm bolt
06 mm bolt
@6 mm bolt
06 mm bolt
@I@@@@:
12 Nm (1.2 m-kg, 8.7 ft.lb)
@8 mm bolt 00:
24 Nm (2.4 m-kg, 17 ft. lb)

TRANSMISSION
@ Main axle @Drive axle
@ 5th pinion gear @2nd wheel gear
@ Circlip 06th wheel gear
@ 3rd pinion gear @3rd wheel gear
@ 6th pinion gear 04th wheel gear
@ 2nd pinion gear 055th wheel gear
@ Bearing @ 1st wheel gear
@ Circlip @Washer
C USE NEW ONE

4. Install:
??Main journal bearing @
To crankcase (Lower) @
NOTE:
Apply molybedenum disulfide oil.
5. Install:
?? Cam cabin @
Onto the crankshaft

?? Crankshaft
assembly @
NOTE:
@The stepped crankshaft end @I should face to
the left.
*Pass the cam chain through the cam chain
cavity. Be sure to attach a retaining wire @to
the cam chain.
TRANSMISSION, SHIFTER AND SHIFT CAM

1. Install:
?? Shift cam assembly @
aGuide bar @
?? Shift fork #I @
?? Shift fork #2 @I
?? Shift fork #3 @
NOTE:
All shift fork letters should face to the left side
and be in sequence (1, 2, 3) beginning from
the left.
4-56

ENGINE ASSEMBLY AND ADJUSTMENT 1 ENG le-1 -
I I
2. Install:
?? Stopper plate (Shift cam) @
?? Stopper lever @
Bolts (Stopper Plate) :

10 Nm (1.0 m-kg, 7.2 ftslb)
Use LOCTI TE@
Bolt (Stopper Lever) :
10 Nm (1.0 m-kg, 7.2 ftslb)
Use LOCTITE@
3. Install:
?? Circlip @
To crankcase ( Lower)
NOTE:
Be sure the circlips @ are inserted into the
lower crankcase positioning grooves.
4. Install:
?? Main axle assembly @
?? Driveaxle assembly @
@Oil seal @
NOTE:
@Be sure the main axle bearing pin @ should
face to front and the drive axle bearing pins
@ should face to rear.
?? Mesh the shift fork #l with the 4th wheel gear
@ and #2 with the 5th wheel gear @ on the
drive axle.
?? Mesh the shift fork #2 with the 3rd pinion
gear @ on the main axle.
*Carefully guide the shift forks so that they
mesh smoothly with transmission gears.
CRANKCASE ASSEMBLY
1. Apply:
aQuick Gasket@
To crankcase matching surfaces.
Quick Gasket@
P/N ACC-11001-05-01
4-57
Before tightening the crankcase bolts, check

the following points:
*Be sure the gear shifts correctly while hand-
turning the shift cam.
2. Tighten:
o Lower crankcase bolt @I
?? Upper crankcase bolt a
(Follow the proper tightening sequence.)
8mmBolt@-@@J:
24 Nm (2.4 m-kg, 17 ft*lb)
6mmBolt @ - @ @ - 8 :
12 Nm (1.2 m-kg, 8.7 ft*lb)
NOTE:
nstall the ground lead @# on bolt No. @ .
nstall the copper washer @ on bolt No. @ .
NOTE:
?? Install the washer @I on bolt No. @ , @I ,
or 0.
3. Install:
@Oil seal stopper CiJ
Bolts (Oil Seal Stopper):

10 Nm (1.0 m-kg, 7.2 ftalb)
4-58
STARTER MOTOR
1. Check:
@O-ring (Starter motor) 0
Damage + Replace.
2. Install:
@Starter motor @
Bolt (Starter Motor) :

10 Nm (1.0 m-kg, 7.2 ft.lb)
OIL PAN AND OIL STRAINER

1. Install:
?? Oil strainer assembly
Bolts (Oil Strainer Assembly):

10 Nm (1.0 m-kg, 7.2 ft- lb) I
2. Install:
?? Oil strainer cover @
?? Relief valve @
NOTE:
The element (window) must be installed verti-
cally against housing arrow mark.
3. Install:
?? Dowel pins
i- ?? Gasket (New)
@Oil pan 0
@Oil level switch @
?? Drain plug @
i
Bolts (Oil Pan):

10 Nm (1.0 rn- kg, 7.2 ft-lb) I
4. Install:
0 Oil filter
0 Oil filter cover @
Bolt (Oil Filter Cover):

15 Nm (1.5 m-kg, 11 ft.lb) I
Refer to the “ENGINE OIL FILTER RE-
PLACEMENT” section in the CHAPTER 3.
4-59
1 ENG lb1
OIL PUMP AND SHIFT SHAFT
1. Install:
?? Shift shaft
NOTE:
Insert the stopper between spring ends.
2. Install:
@Dowel pin @
*Gasket (New) @
3. Install:
@Oil pump assembly @
NOTE:
Align the oil pump arrow mark @ with crank-
case arrow mark 0.
WATER PUMP
1. Install:
@Water pump housing @
Bolts (Water Pump Housing):

10 Nm (1.0 m-kg, 7.2 ft.lb)
2. Install:
?? O-ring
?? Water pump cover (iJ
Bolts (Water Pump Cover) :

10 Nm (1.0 m-kg, 7.2 ft.lb) I
4-60
A.C. MAGNETO
@ Magneto
@ Stator coil assembly
@ Pickup coil
ST PSOR COlC REs\sT ANCE-. I

0.44 - 0.66R at 20°C (68’F)
(White -White)
PICKUP COIL RESISTANCE:

85 - 115R at 20°C (68°F)
(White/Red -White/Black)
10 Nm (1.0 m-kg, 7.2 ftmlb)
80 Nm (8.0 m-kg, 58 ftelb)
4-61

A.C. MAGNETO
1. Install:
?? Stator coil assembly @
?? Pickup coil @
*Woodruff key @
Bolts (Stator Coil Assembly):

10 Nm (1.0 m-kg, 7.2 ftslb)
Use LOCTITE@
Screws (Pickup Coil):
5 Nm (0.5 rn. kg, 3.6 ft. lb)
NOTE:
@Clean the tapered portions of the crankshaft
and magneto.
?? When installing the magneto, make sure the
woodruff key is properly seated in the key way
of the crankshaft.
2. Install:
@Magneto @
?? Bolt (Magneto)
3. Attach :
?? Universal Rotor Holder @
NOTE:
Hold the magneto to tighten the nut by the
Universal Rotor Holder @ .
Universal Rotor Holder:

P/N Y U-01 235
4. Tighten:
?? Bolt (Magneto)
4-62
CLUTCH
@Primary driven gear @O-ring 0 Thrust washer
@Thrust washer @ Lock washer @I Spacer
@ Clutch boss @Boll @ Bearing
@ Friction plate @Oil seal
@Clutch plate @Push rod #2
@ Pressure plate @Push lever assembly
@Clutch spring g:o: screw housing
@ Push rod # 1 1 0 ar
SPRING FREE LENGTH

LIMIT:
29.0 mm (1.142 in)
CLUTCH PLATE
B WARP LIMIT:
0.1 mm (0.004 in)
16 Nm (Oik-,
FRICTION PLATE
C WEAR LIMIT:
2.8 mm (0.11 in)
i
16 Nm (1.6 m*kg, 11 ft-lb)
4-63
CLUTCH
1. Install:
*Collar 0
*Thrust washer @
*Clutch housing @
?? Bearing @
*Spacer @
?? Thrust washer @
.Clutch boss @
?? Lock washer (New) @
NOTE:
Install the bearing @ and spacer @after installa-
tion of the clutch housing @ .
2. Tighten:
Use the Universal Clutch Holder @ .
NOTE:
Hold the clutch boss to tighten the nut by
Universal Clutch Holder @ .
P/N Y M-91 042
Nut (Clutch Boss) :

70 Nm (7.0 m-kg, 50 ft.lb) I
NOTE:
Bend the lock washer tab along the nut flat.
3. Install:
@Push rod #2 @
.Boll 0
*Push rod #l @
?? Friction plates
?? Clutch plates
4-64
4. Install:
0 Pressure plate
Be sure the match mark @ on the clutch boss is

aligned with the match mark @on the pressure
plate.
5. Install:
@Clutch springs @
?? Bolts (Clutch spring) @
Bolts (Clutch Spring) :

6 Nm (0.6 m-kg, 4.3 ft. lb) I
6. Install:
?? Dowel pins
?? Gasket (Crankcase cover)
*Crankcase cover (Right) @
Bolts (Crankcase Cover) :

10 Nm (1.0 m-kg, 7.2 ft.lb) I
STARTER CLUTCH
1. Install:
,* ?? Idle gear @
?? Idle gear @
*Starter clutch gear @

?? Woodruff key @
2. Install:
@Starter clutch @
?? Washer
?? Bolt (Starter clutch)
Bolt (Starter Clutch) :

80 Nm (8.0 m-kg, 58 ft-lb) I
4-65
STARTER CLUTCH
@ Starter drive gear @ Starter clutch gear
@ Idle gear @) W o o d r u f f k e y
@ Idle gear @ Washer
@ Shaft
@ Starter clutch assembly
4-66
ENGINE ASSEMBLY AND ADJUSTMENT m
PISTON AND CYLINDER
@Top ring @Dowel pin
@Oil ring (Lower) @Cylinder
@Oil ring (Upper) @I O - r i n g
@Second ring @Gasket (Cylinder)
@Circlip @! Piston ring
@Piston pin
@Piston
SIDE CLEARANCE LIMV

Top: 0.10 mm (0.004 in) I
2nd: 0.10 mm (0.004 in)
EN0 GAP:
8 Top: 0.15 - 0.30 mm I

B (0.0059 - 0.0118 in)
/ 2nd: 0.15 - 0.30 mm
PISTON-TO-CYLINDER
CLEARANCE:
0.04 - 0.06 mm
(0.0016 - 0.0024 in)
r
/ 7 N m ( 0 . 7 m - k g , 5 . 1 ft.lb) 1
JD( uSENEWONE I W _
4-67

-1
3. Install:
?? Dowel pins
@Gasket (Stater clutch cover) (New)

?? Stater clutch cover @
Bolts (Stater Clutch Cover):

10 Nm (1.0 m-kg, 7.2 ft-lb) I
PISTON AND CYLINDER

1. Install:
aPiston rings
NOTE:
Be sure to install rings so that Manufacturer’s
marks or numbers are located on the top side of
the rings. Oil the pistons and rings liberally.
2. Install:
0 Piston pins
0 Pistons
?? Circlips (Piston pin) @
NOTE:
@Be sure the piston arrow mark @ face to ex-
haust side of the engine.
?? Before installing the piston pin circlip, cover
the crankcase with a clean rag to prevent the
circlip from falling into the crankcase cavity.
?? Be sure the marked piston numbers @ should
be in sequence (1, 2, 3, 4) begining from the
left.
Always use new circlips (Piston pin).
4-68

3. Install:
?? Gasket (Cylinder) @
?? Dowel pins
4. Lubricate:
0 Pistons
0 Piston rings
?? Cylinder
NOTE:
Apply a liberal coating of 4stroke engine oil.
5. Position:
Offset the piston ring end gaps.
stop ring end @
??Oil ring end (Lower) @
*Oil ring end (Upper) @
?? 2nd ring end @
6. Install:
?? Cylinder
NOTE:
??Install pistons #2 and #3 first.
?? Pass the cam chain and cam chain guide (E>
haust side) through the cam chain cavity.
7. Install:
0 O-ring
*Water pipe @
8. Turn:
?? Crankshaft
Counterclockwise.
9. Align:
?? “T” mark
*Stationary pointer
Refer to “ E N G I N E D I S A S S E M B L Y -
CYLINDER HEAD AND CAMSHAFT”.
NOTE:
When # 1 piston is at TDC.
4-69
CYLINDER HEAD AND CAMSHAFT
Cylinder Head
@Washer @Valve guide
@ Rubber washer @ Circlip
@ Gasket (Cylinder head cover) @Gasket (Cylinder head)
@ Spark plug (@Cylinder head cover
@ Nut @Cylinder head assembly
@Washer
110 Nm (I.0 m-Kg, I.L ~t-ll)) )
1=:/CT\
25 Nm (2.5 m-kg, 18 ft.7
10 Nm (1.0 m-kg, 7.2 ft.lb)
c . I
01 C 1 USE NEW ON4
4-70
Camshaft
@Camshaft (Intake) @ Spring seat @Camshaft (Exhaust)
@Cam chain sprocket @ Oil seal @ Chain guide (Upper)
@ Valve lifter @ Intake valve 0 Cam chain
@ Valve pad (@ Exhaust valve @Cam chain guide (Exhaust side)
@ Valve retainer @ Cam chain tensioner @ Match mark
@Spring seat @Gasket (Cam chain tensioner)
0 Valve spring @Cam chain guide (Intake side)
A B
VALVE CLEARANCE
~____
INTAKE:
0.11 - 0.20 mm
__-___
(COLD):
F
(0.004 - 0.008 in)
EXHAUST:
C 0.21 - 0.30 mm
(0.008 - 0.012 in)
-.-___ I
.4 m*ka. 17 ft.lb)

CYLINDER HEAD AND CAMSHAFT
1. Install:
@Gasket (Cylinder head) (New) @
?? Dowel pins @
NOTE:
The gasket “HEAD” mark should face upward.
NOTE:
aSelect either of the two procedures explained
in this manual, as follows:
?? Procedure 1.
The cam chain is disconnected + Connect.

@Procedure 2.
The camshafts are removed + Install.
Procedure 1
1. Install:
?? Camshafts, and cylinder head assembly
*Be sure the camshaft timing marks @ align

with the camshaft cap marks 0.
aBe sure the “T” mark on the magneto align
the stationary pointer when #l p i s t o n i s
at TDC.
2. Tighten:
Use the Hexagon Wrench 6 mm (0.24 in)

0.
NOTE:
Tighten the nuts in their proper tightening
sequence and torque nuts in two stages.
Nuts (Cylinder Head):

25 Nm (2.5 m-kg, 18 ft-lb)
4-72

4. Connect:
?? Cam chain
With the chain joint (New).

Use the Cam Chain Cutter @ .
Cam Chain Cutter:

P/N YM-01112
NOTE:
Keep the cam chain as tense as possible on the
exhaust side.
5. Go to “CAM CHAIN TENSIONER”.

Procedure 2.
1. Install:
?? Camshaft case and cylinder head assembly
2. Tighten:
Use the Hexagon Wrench 6 mm (0.24 in).
Tighten the nuts in their proper tightenin<

sequence and torque nuts in two stages.
Nuts (Cylinder Head):

25 Nm (2.5 m-kg, 18 ft. lb)
3. Install:
?? Camshafts
Camshaft installation steps:

*Turn the crankshaft counterclockwise.
@Align the “T” mark @ on the magneto wir th
the crankcase end @ when #l piston is
at TDC.
I A CAfXl-KM:
Do not turn the crankshaft during the cam-
shafts installation. Damage or improper valve
timing will result.

ENGINE ASSEMBLY AND ADJUSTMENT pi&j
?? Lubricate the camshaft bearing surfaces,

cam lobes and cam journals.
Molybdeum Disulfide Oil
o Install the exhaust camshaft (IJ first, then

install the intake camshaft @ .
?? Be sure the timing marks @I on the camshaft
face upward.
II Keep the cam chain as tense as possible on
the exhaust side.
?? Remove the retaining wire @ .
Do not turn the camshaft separately or

damage to the piston and valve will result.
y Install the dowel pins.

??Install the camshaft caps.
@Align the camshaft timing marks @ with the
camshaft cap marks @ .
NOTE:
*The numbers are punched on the camshaft
caps in increments from right to left.
?? Do not install the bolts at $6 marked place in
this stage.
?? Tighten the bolts (Camshaft caps).
NOTE:
Tighten the camshaft caps in a crisscross
pattern from innermost to outer caps.
A CAW-ION:
The cam caps must be tightened evenly or
damage to the cylinder head, camshaft caps
and cam will result.
Bolts (Camshaft Cap):

10 Nm (1 .O me kg, 7.2 ft. lb)
4. Install:
@Cam chain guide (Exhaust side) @
4-74

CAM CHAIN TENSIONER
1. Position:
Cam chain
??
Exhaust side -+ Tense.

Intake side + Slack.
2. Install:
Cam chain tensioner installation steps:

?? Remove the tensioner end cap bolt and
spring.
?? Release the cam chain tensioner one-way
cam @ and push the tension rod @ .

?? Install the tensioner with a new gasket into
the cylinder.
Bolts (Cam Chain Tensioner) :

10 Nm (1.0 m-kg, 7.2 ft-lb)
?? Install the collar @ , springs @ , washer @

and end cap bolt 0.
End Cap Bolt (Cam Chain Tensioner):

20 Nm (2.0 m-kg, 14 ft.lb)
3. Turn:
?? Crankshaft
Counterclockwise for a several turns.

4. Inspect:
?? Camshaft timing marks @
Align with the camshaft cap marks @ .

a Crankshaft “T” mark @
Align with the crankcase end 0.
Out of alignment + Adjust.
Refer to “CAMSHAFT INSTALLATION
STEPS”.
5. Install:
?? Gasket (Cylinder head cover)
Bolts (Cylinder Head Cover):

10 Nm (1.0 m-kg, 7.2 ft-lb) I
4-75

6. Install:
?? Washers (New)
?? Oil delivery pipe @
?? Union bolts @I
7. Install:
?? Dowel pins
?? Generator cover @
Bolts (Generator Cover):

10 Nm (1.0 m-kg, 7.2 ftslb) I
REMOUNTING ENGINE
When remounting the engine, reverse the removal
procedure. Note the following points.
1. Install:
?? Engine assembly
@Bolt (Engine mount - Rear Lower) @

*Bolt (Engine mount - Rear Upper) @
Bolt (Engine Mount - Rear Lower):

45 Nm (4.5 m-kg, 32 ftslb)
Bolt (Engine Mount - Rear Upper):
55 Nm (5.5 me kg, 40 ft. lb)
@Collars
2. Install:
?? Down tube frames (Left and right) @
?? Bolt (Engine - Mount) @
Bolts (Down Tube Frame - Lower):

33 Nm (3.3 m-kg, 24 ftmlb)
Bolts (Down Tube Frame - Upper):
60 Nm (6.0 m-kg, 43 ftalb)
Use LOCTITE@
Bolt (Engine Mount) :
55 Nm (5.5 rn. kg, 40 ftslb)
4-76
3. Install:
*Starter lever @
@Cover @
Bolt (Starter Lever) :

8 Nm (0.8 ma kg, 5.8 ft. lb)
4. Install:
?? Drive chain @
?? Drive sprocket @
?? Lock washer (New) @
?? Nut (Drive sprocket) @
Nut (Drive Sprocket) :

70 Nm (7.0 me kg, 50 ft. lb)
NOTE:
Adjust the drive chain slack if necessary.
5. Install:
*Cover (Crankcase Left)
*Shift arm
Bolts (Crankcase Cover) :

10 Nm (1.0 m-kg, 7.2 ft*lb)
Use LOCTITE@
Bolt (Shift Arm) :
10 Nm (1.0 m-kg, 7.2 ft-lb)
6. Install:
?? Muffler assembly
7. Tighten :
?? Flange nuts (Exhaust pipe)
8. Tighten:
?? Bolt (Muffler stay) (For California only

0
Bolt (Muffler Bracket):

20 Nm (2.0 m-kg, 14 ftslb)
Bolt (Muffler Stay -
For California only):
20 Nm (2.0 m-kg, 14 ftelb)
4-77

YAMAHA EXHAUST VARIABLE VALVE (For California Only)
1Exhaust pipe assembly @ Bracket
Gasket (Exhaust pipe) @ Cables
Bush @Washer
Oil seal @ Pulley
Gasket @ Valve cover
Shaft arm @ Gasket (Muffler)
Housing @ Muffler assembly
1 20 Nm (2.0 m-kg, 14
A USE NEW ONE
I”
lONm( 1.0 m-kg 7.2 ft.lb)
5 Nm (0.5 m-kg, 3.6 ft.lb)

9. Install (For California only):
?? Shaft arm
*Gasket @
@Housing @
IO. Install (For California only):

?? Washer
?? Bracket
Bolts (Bracket):
10 Nm (1.0 m-kg, 7.2 ftslb)
11. Install (For California only):

@Pulley @
@Cables @
@Clips @
12. Adjust (For California only):

?? Cable
Refer to the “EXUP CABLE ADJUST-

13. Adjust:
*Throttle cable

(Throttle Gripe):
2 - 5 mm (0.08 - 0.20 in)
Refer to the “THROTTLE CABLE FREE

PLAY ADJUSTMENT” section in the
CHAPTER 3.
4-79

14. Adjust:
@Clutch cable
Clutch Cable Free Play:

2 - 3 mm (0.08 - 0.12 in)
Refer to the “CLUTCH ADJUSTMEI

15. Fill:
?? Coolant
Total Amount:
1.0 L (0.9 Imp qt, 1.1 US qt)
Refertothe”COOLANT REPLACEME
16. Fill:
?? Engine oil
KY
6
Total Amount:
0.8 L (0.7 Imp qt, 0.84 US qt)
Refer to the “ENGINE OIL REPL

4-80
R A D I A T O R COOL #
\
COOLING SYSTEM
RADIATOR
@ Radiator assembly @ Hose (Radiator - Outlet)
@ Fan motor assembly @Outlet pipe
@ Radiator cap assembly @O-ring
@ Radiator cap @Hose (Radiator - Inlet)
0 Radiator cover
) RADIATOR CAP OPENING PRESSURE: -1

A 74-103kPa
(0.75 - 1.05 kg/cm’, 10.7 - 14.9 psi)
4 1~ 10Nm (l.Om.kg, 7.2ft.Ib)
COOLANT CAPACITY:
h
B 19 L (1.7 Imp qt, 2.0 US qt)
lncludinq all routes I-Q
\ ‘\
\
‘?
P I
I
I
/
/ 1)
10 Nrn (1.0 m-kg, 7.2 ftelh) ;
‘i\
7 Nm (0.7 m.kg, 5.1 ftelh) 1
1-C i USE NEW ONE ]
10 Nm (1.0 m-kg, 7.2 f t - l b ) 1

~_
7Nm(0.7m~kg,5.1ft~Ib)
5-l
RADIATOR COOL %
REMOVAL
1. Remove:
?? Lower cowlings (Left and Right)
?? Side cowlings (Left and Right)

Refer to the “COWLING REMOVAL ANC
I N S T A L L A T I O N - R E M O V A L ” sectiol
in the CHAPTER 3.
2. Drain:
0 Cooling system
Refer to the”COOLANT REPLACEMENT
3. Remove:
?? Muffler assembly
NOTE:
Thoroughly flush the cooling system with cles
tap water.
ACAUTION:
Take care so that coolant does not splash 1
painted surfaces. If splashes, wash it awi
with water.
Do not remove the radiator cap, drain bol

and hoses especially when the engine ar
radiator are hot. Scalding hot fluid and stea
may be blown out under pressure, which cou
cause serious injury. When the engine has coole
place a thick rag like a towel over the radiat
cap, slowly rotate the cap counterclockwi
to the detent. This procedure allows any reside
pressure to escape. When the hissing sound r
stopped, press down on the cap while turni
counterclockwise and remove it.
4. Disconnect:
?? Hose (Radiator - Inlet) @
?? Hose (Radiator - Outlet) @
5-2
6. Remove:
?? Fan motor assembly
INSPECTION
1. Inspect:
?? Radiator core
Obstruction + Blow out with compressed

air through rear of the radiator.
Flattened fin + Repair/replace.
2. Inspect:
?? Hose (Radiator - Inlet)
?? Hose (Radiator - Outlet)
0 Outlet pipe
Cracks/Damage --f Replace.
3. Measure:
?? Radiator cap opening pressure
Radiator cap opens at pressure below the

specified pressure + Replace.
Radiator Cap Opening Pressure:

74 - 103 kPa
(0.75 - 1.05 kg/cm’, 10.7 - 14.9 psi)
5-3

Measurement steps:
@Attach the Cooling System Tester @ and
Adapter @ to the radiator cap @ .
Cooling System Tester:

Y U-24460-0 1
Adapter:
Y U-33984
1 ?? Apply the specified pressure for 10 seconds,

I and make sure there is no pressure drop.
INSTALLATION
1. Install:
?? Fan motor assembly
Screws (Fan Motor Assembly):

10 Nm (1.0 mm kg, 7.2 ft. lb)
2. Install:
?? Radiator
%’ Bolts (Radiator):
7 Nm (0.7 me kg, 5.1 ft. lb)
3. Fill:
0 Cooling system
R e f e r t o t h e “COOLANT REPLAC
4. Inspect:
0 Cooling system
Decrease of pressure (leaks) + Repair
required.
5-4
Inspection steps:
@Attach the Cooling System Tester @ to the
radiator.
Cooling System Tester:

Y U-24460-0 1
?? Apply 100 kPa (1 .O kg/cm*, 14 psi) pressure .

@Measure the indicated pressure with the
gauge.
5-5

WATER PUMP AND THERMOSTATIC VALVE I
COOL
WATER PUMP AND THERMOSTATIC VALVE

@ Hose 3 0 Pipe 2 @O-ring
@ T h ermostatic cover @Pipe 1 @Water pump cover
@ Thermostatic @Water jacket joint @O-ring
@ Thermostatic housing 8 ($Jng @Water pump housing
@ Hose 1 ring C@ O-ring

@ Hose 2 @Water pipe
THERMOSTATIC VALVE OPENING
I lnhlmfi nm.kn 73ft.lhl
/ 6 / USE NEW ONE
~_ /
B USE NEW ONE
5-6

WATER PUMP AND THERMOSTATIC VALVE r-ml
COOL
REMOVAL
1. Remove:
0 Seat
?? Top cover
INSTALLATION - REMOVAL” section
in the CHAPTER 3.
2. Drain:
0 Cooling system
Refer to the”COOLANT REPLACEMENT”
3. Remove:
?? Fuel tank
4. Disconnect:
?? Crankcase ventilation hose @
lair vent hose @

5. Remove:
?? Air filter case @
6. Disconnect:
whose 1 @
?? Hose2 @
?? Hose 3 @

WATER PUMP AND THERMOSTATIC VALVE rJ%l
COOL
7. Disconnect:
?? Thermo unit lead @
?? Thermo switch lead @
8. Remove:
?? Thermostatic housing
9. Remove:
?? Thermostatic cover @
?? Thermostatic @
10. Remove:
?? Shift arm
11. Remove:
?? Water pipe 0
5-8
WATER PUMP AND THERMOSTATIC VALVE I-fw
12. Remove:
@Water pipe (Q
0 Water pump cover @
13. Remove:
?? Water pump housing @
@O-ring
INSPECTION
1. Inspect:
?? Thermostatic valve
Valve does not open at 80 - 84°C (176 -

183” F) + Replace.
Inspection steps:
*Suspend thermostatic valve @ in a vessel
0.
?? Place reliable thermometer in a water 0.
??Head water slowly.
aObserve t h e r m o m e t e r @ , w h i l e s t i r r i n g
water continually.
323 003 NOTE:

Thermostatic valve is sealed and its setting is
specialized work. If its accuracy is in doubt,
always replace it. A faulty unit could cause
serious overheating or overcooling.
5-9

WATER PUMP AND THERMOSTATIC VALVE pqjiq
2. Inspect:
0 Impeller
Cracks/Wear/Damage + Replace.
INSTALLATION
1. Install:
0 Water pump cover
0 Pipe
o Shift arm
?? Thermostatic cover
Bolts (Water Pump Cover):

10 Nm (1.0 ma kg, 7.2 ftalb)
Bolts (Pipe) :
10 Nm (1.0 ma kg, 7.2 ft*lb)
Bolts (Crankcase Cover - Left):
10 Nm (1.0 me kg, 7.2 ft*lb)
Bolt (Shift Arm):
10 Nm (1.0 ma kg, 7.2 ft*Ib)
Bolts (Thermostatic Cover) :
10 Nm (1.0 m-kg, 7.2 ftslb)
~BCAWWN:
Always use new O-ring.
2. Fill:
0 Cooling system
Refer to the “COOLANT REPLACEMENT’
3. Inspect:
0 Cooling system
Decrease of pressure (Leaks) + Repair as
required.
5-10

CARBURETOR piqq
CARBURETOR
CARBURETOR
@ Upper bracket 0 Valve seat assembly r SPEClf CATIONS
@ Throttle stop screw @ Pilot jet ID Mark 3BF-00
@ Fuel overflow hose @ Main jet (Except for California),
@ Lower bracket @ Starter plunger assembly 3FH-00
(For California)
0 SY ncronizing screw @ Pilot screw
MAIN JET #87.5
@ Float @ Piston valve assembly MAIN AIR JET #60
0 Float pin 0 Jet needle set PI LOT JET #15
@ Float chamber @ Starter lever shaft PILOT AIR JET #I30
@ Needle jet @ O-ring JET NEEDLE 5CFZ2
@ Fuel drain screw PILOT SCREW 3 %
THROTTLE VALVE #I30
ENGINE IDLE SPEED 1,250 - 1,350 r/min
FUEL LEVEL 4.5 - 6.5 mm (0.18 - 0.26 ir
13 Nm (0.3 me kg, 2.2 ft. lb)
6-1

CARBURETOR I-
SECTION VIEW A CAUtlON;

@Starter air bleed @Main air jet @Pilot outlet The pilot screw settings are adjusted fa
@ Starter air bleed pipe @)Pilot air jet 1 @Pilot screw maximum performance at the factory.
@Air vent @Fuel inlet @Main jet
@ Air inlet
Any attempt to change these settings w
@Float needle valve @Main bleed pipe
@ Mixture outlet @Valve seat @Needle jet II decrease engine performance.
@Starter plunger @Pilot jet @Jet needle
@Starter jet No 1 @Float @Spring clip
@Starter jet No. 2 @Throttle valve @Piston valve
@Pilot air jet 2 @Bypass hole
6-2
CARBURETOR -1
REMOVAL
1. Remove:
0 Seat
a Top cover
in the CHAPTER 3.
2. Turn the fuel cock to “OFF” position.

3. Remove:
?? Fuel cock lever @
4. Disconnect:
?? Fuel hose @
5. Remove:
?? Fuel pump @
Gasoline is highly flammable.

Avoid spilling fuel on the hot engine.
6. Remove:
?? Fuel tank bracket @
7. Remove:
?? Fuel tank @
6-3
C A R B U R E T O R CARB #
8. Disconnect:
?? Crankcase ventilation hose @
?? Air vent hose @
9. Remove:
?? Air filter case @
10. Loosen :
0 Screw (Starter cable clamp)
11. Disconnect:
?? Starter cable @
12. Disconnect:
?? Fuel hose @
13. Loosen :
*Screws (Carburetor joint clamp - UI
0
14. Remove:
?? Carburetor assembly
15. Disconnect:
*Throttle cable 1 @
aThrottle cable 2 @
6-4
CARBURETOR (CARBII
DISASSEMBLY
NOTE:
The following parts can be cleaned and in-
spected without carburetor separation.
?? Throttle valve
0 Piston valve
0 Starter plunger
?? Float chamber components
1. Remove:
*Bracket (Upper) @
~Bracket (Lower) @
@Starter lever shaft @
2. Remove:
???????
*Spring 0
@Starter plunger @
3. Remove:
?? Vacuum chamber cover @
?? Spring @
?? Piston valve assembly @
4. Remove:
?? Plug (Jet needle) 0
*Spring @
?? Washer @
aJet needle @I
6-5

[CARB(
CARBURETOR
5. Remove:
0 Pilot screw
6. Remove:
?? Float chamber cover
*Gasket
*Float pin @
*Float @
@Valve seat screw @
*Valve seat assembly @
7. Remove:
?? Main jet @
?? Holder (Main jet) @
?? Washer @
0 Pilot jet 0
?? Needle jet @
?? Pilot air jet 8
INSPECTION
1. Inspect:
?? Carburetor body
?? Floatchamber
?? Fuel passage
Contamination + Clean as indicated.
Carburetor cleaning steps:

*Wash carburetor in petroleum based sol\
(Do not use any caustic carburetor clea
solution. 1
*Blow out all passages and jets with a
pressed air.
2. Inspect:
?? Floats
Damage4 Replace.
6-6
CARBURETOR ~CARB~ j@ 1
3. Inspect:
*Float needle valve @
0 Valve seat @
?? O-ring @
Damage/Wear/Contamination+Replace as
a set.
4. Inspect:
*Throttle valve
Scratches-+Replace.
*Rubber diaphragm
Tears+ Replace.
5. Inspect:
?? Needle jet @
?? Main jet @
?? Holder @
0 Pilot jet @
?? Pilot adjust screw @
0 Pilot air jet @

Bends/Wear/Damage -+ Replace.
Contamination + Blow out jets with a
compressed air.
6. Check:
*Free movement
Insert the throttle valve into the carburetor
body, and check for free movement.
Stick- Replace.
6-7
CARBURETOR
ASSEMBLY
To assemble the carburetor, reverse the disassem-
bly procedures. Note the following points.
?? Before reassembling, wash all parts in clean

gasoline.
?? Always use a new gasket.
1. Install:
?? Piton valve assembly
NOTE:
Note position of tab @ on diaphragm. This tab
must be placed in the cavity of the carburetor
body during reassembly.
2. Install:
?? Float chamber cover
*Vacuum chamber cover
3. Connect:
?? Throttle shaft
Throttle valves must be fully closed.
4. Install:
?? Starter lever shaft

CARBURETOR pg-j
5. Installer:
*Upper bracket @
glower bracket @
Screw (Upper Bracket):

3 Nm (0.3 m-kg, 2.2 ftelb)
Screw (Lower Bracket):
5 Nm (0.5 m-kg, 3.6 ft.lb)
INSTALLATION
1. Install:
?? Fuel tank @
Bolts (Fuel Tank):

14 Nm (1.4 ma kg, 10.2 ft- lb)
2. Install:
?? Fuel tank bracket @
Bolts (Fuel Tank Bracket):

10 Nm (1.0 m-kg, 7.2 ft.lb)
3. Install:
?? Fuel pump @
Bolt (Fuel Pump):

8 Nm (0.8 m - kg, 5.6 ft - lb)
6-9
CARBURETOR m
ADJUSTMENT
NOTE:
Before adjusting the fuel level, the float heigl
should be adlusted.
The pilot screw settings are adjusted f

maximum performance at the factory. A
attempt to change these settings \II
decrease enaine performance.
Fuel Level Adjustment

1. Measure:
.Fuel level @
I&
Out of specification+Adjust it by the folio
ing adjustment steps.
n.5-6.5mm
Fuel level measurement steps:

?? Place the motorcycle on the level place.
?? Connect the Fuel Level Gauge (YM-013
to the carburetor 0.
?? Place the Gauge vertically next to the fl
chamber line @ .
?? Loosen the drain screw @ .
?? Warm up the engine, then shut it off aft!
few minutes.
?? fvleasure the fuel level. It should be wii
the specified range.
NOTE:
Fuel level readings of both side of carburN
line should be equal.
6-10
CARBURETOR (CARBI
2. Adjust:
?? Fuel level
Fuel level adjustment steps:

*Remove the carburetor assembly.
Refer to “REMOVAL” section.
*Remove the float, valve seat and the needle
valve.
?? inspect the valve seat and the needle valve.
If either is worn, replace as a set.
*If both are fine, adjust the float height by
bending the float tang 0.
@Recheck the fuel level.
6-11
FRONT WHEEL pii&G
CHASSIS
FRONT WHEEL
@ Gear unit assembly @ Bearing
@ Oil seal @ Spacer
@ Meter clutch @ Collar
@ Clutch retainer @ Wheel axle
* Load is the total weight of cargo, rider, passenger,anc

accessories.
-1
Bi
1 lo/70 R17-53H
r WEAR LIMIT:
1.0 mm -
(0.04 in)
1
i
1R I M S I Z E :
’ i MT3.00 X 17 I
D / RIM RUNOUT LIMIT: /
-I
7-l

FRONT WHEEL Ml
REMOVAL

2, Remove:
?? Speedometer cable @
3. Remove:
?? Brake calipers (Right/Left)
4. Loosen:
?? Pinch bolt (Front axle) @
?? Axle (Front) @
5. Elevate the front wheel by placing a suitablt

6. Remove:
?? Axle @
?? Wheel (Front)
?? speedometer gear unit
NOTE:
Do not squeeze the brake lever while the wheel i!
off the motorcycle.
INSPECTION
1. Inspect:
?? Tire
Tire tread shows crosswise lines (minimun
tread depth)/Cracks + Repalce.
Minimum Tire Tread Depth:

1.0 mm (0.04 in)
w I I @ Tread depth @ Side wall @ Wear indicator
2. Inspect:
?? Front axle
Bends + Replace.
Roll the axle on a flat surface.
dcl
Do not attempt to straighten a dent axle.
34” “08
7-2

r FRONT WHEEL -1
3. Inspect:
?? Wheel
Cracks/Bends/Warpage A Replace.
4. Measure:
?? Wheel runout
Over specified limit + Repalce.
Rim Runout Limits:

Radial @ : 2.0 mm (0.08 in)
Lateral @ : 2.0 mm (0.08 in)
@After mounting a tire, ride conservatively to

allow proper tire to rim seating. Failure to do
so may cause an accident resulting in motor-
cycle damage and possible operator injury.
?? After a tire repair or replacement, be sure to
torque tighten the valve stem locknut @ to

specification.
Valve-stem Locknut:
1.5 Nm (0.15 rn. kg, 1.1 ft. lb) I
5. Inspect:
?? Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly + Repalce.
Wheel bearing replacement steps:

?? Clean the outside of the wheel hub.
?? Remove the bearing using a general bearing
puller @I .
?? Install the new bearing by reversing the
previous steps.
7-3
FRONT WHEEL -1
NOTE:
Use a socket @ that matches the outside
diameter of the race of the bearing.
I A CAUTION:
Do not strike the center race or balls of the

bearing. Contact should be made only with
the outer race.
6. Inspect:
?? Brake disc
Wear/Over specified limit --f Replace.
Maximum Deflection:
(Front and Rear) :
0.5 mm (0.02 in)
Minimum Disc Thickness
Front:
3.5 mm (0.14 in)
INSTALLATION
When installing the front wheel, reverse t
removal procedure. Note the following points.
1. Lublicate:
?? Bearings
0 Oil seals
M Lithium - Soap Base Grease
2. Install:
?? speedometer gear unit
Be sure that the two projections inside 1

wheel hub mesh with the two slots in the g
unit assembly.
7
I
I FRONT WHEEL
3. Install:
?? Front wheel
NOTE:
Be sure that the projecting portion (torque
stopper) 0 of the gear unit housing is position-
ed correctly.
4. Tighten:
?? Front axle
?? Pinch bolt (Front axle)
?? Brake calipers (Right/Left)
?? Speedometer cable
Front Axle:
58 Nm (5.8 rn. kg, 42 ft. lb)
Pinch Bolt (Front Axle):
20 Nm (2.0 rn. kg, 14 ftslb)
35 Nm (3.5 m-kg, 25 ft. lb)
Make sure that the brake hoses are routed prop-

erly.
@Brake hose
@Brake hose holder
NOTE:
*After replacing the tire and/or rim, wheel
balancer should be adjusted.
*Adjust the wheel balance with brake disk
installed.
1. Remove:
*Balancing weight
7-5

FRONT WHEEL liiii&Gl
2. Set the wheel on a suitable stand.
3. Find:
?? Heavy spot
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “XI ” mark on the wheel bottom
spot.
c. Turn the wheel so that the “XI” mark is
900 up.
d. Let the wheel fall and wait for it to rest. Put
an “X2” mark on the wheel bottom spot.
e. Repeat the above b., c., and d. several
times until these marks come to the same
spot.
f. This spot is the heavy spot “X”.
4. Adjust:
*Wheel balance
Adjusting steps:
*Install a balancing weight 0 on the spoke
exactly opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
*Turn the wheel so that the heavy spot is 90°

I up.
*Check that the heavy spot is at rest there.
If not, try another weight until the wheel is
balanced.
5. Check:
*Wheel balance
Checking steps:
*Turn the wheel so that it comes to each point
as shown.
*Check that the wheel is at rest at each point.
If not, readjust the wheel balance.
7-6
REAR WHEEL -1
REAR WHEEL
@ Collar
@ Oil seal
COB e a r i n g
@ Spacer
@ Clutch hub
@ Collar
@) Cotter pin
@T ension bar
@ Brake hose holder
I
A TIRE SIZE:
140/60R 18-64H
~_ -~
4
1 .O mm (0.04 in)
RIM RUNOUT LIMIT:

RADIAL:
D 2.0 mm (0.08 in)
LATERAL:
2.0 mm (0.08 in)
28 Nm (2.8 m - kg

REAR WHEEL ~
REMOVAL
Securely support the motorcycle so there is nc

2. Elevate the rear wheel by placing a suitabk

stand under the swing arm.
3. Remove:
?? Brake caliper
NOTE:
Do not depress the brake pedal while the calipe
is off the disc.
4. Loosen:
?? Lock nut @
?? Adjuster @
5. Remove:
*Cotter pin
?? Axle nut
@Axle @
?? Rear wheel
INSPECTION
1. Inspect:
aTire
?? Rear axle
?? Wheel
?? Wheel bearings
?? Brake disc
Refer to the “FRONT WHEEL - INSPEC
TION”.
2. Measure:
?? Wheel runout
Refer to the “FRONT WHEEL - INSPE(

TION”.
7-8
REAR WHEEL -1
INSTALLATION
When installing the rear wheel, reverse the re-
moval procedure. Note the following points.
1. Lubricate:
?? Bearings
0 Oil seals
0 Spacer
*Collar
Lithium - Soap Base Grease
2. Adjust:
Drive Chain Slack:

10 - 20 mm (0.4 - 0.8 in)
Refer to the “DRIVE CHAIN ADJUST-

3. Tighten:
?? Nut (Rear axle)
?? Brake caliper
Nut (Rear Axle):

107 Nm (10.7 me kg, 77 ft. lb)
35 Nm (3.5 rn. kg, 25 ft. lb)
Do not loosen the axle nut after torque tighten-

ing.
NOTE:
?? After replacing the tire and/or rim, wheel
balance should be adjusted.
*Adjust t h e w h e e l b a l a n c e w i t h b r a k e d i s c
and wheel hub installed.
1. Adjust:
?? Wheel balance
Refer to the “FRONT WHEEL - STATIC
WHEEL BALANCE ADJUSTMENT”
7-9

@ Master cylinder cap @ Brake caliper ? The arrow mark @ on the pad spring must pointing the
@ Rubber seal g Fad spring disc rotating direction.
@ Master cylinder kit rston
@ Master cylinder @ Piston seal
@ Brake hose @ Dust seal
@ Union bolt 0 Brake pad
@ Copper washer @ Brake disc
@ Joint .
BRAKE FLUID TYPE:

A DOT#4 2 Nm (0.2 m-kg, 1.4ft.lb
If DOT #4 is not available, iI-
I
#3 can be used.
BRAKE PAD WEAR LIMIT:

B
0.5 mm (0.02 in)
BRAKE DISC WEAR LIMIT:
3.5 mm (0.14 in)
,/ 120 Nrn (2.0 m -~kg, 14 ft - lb) ]
7-10

@ Reservoir tank cap @ Union bolt
@ Bush 0 Copper washet
@ Diaphragm @Brake caliper
@ Reservoir tank @Piston
@ Reservoir hose @ Piston seal
@ Master cylinder @ Dust seal
0 Master cylinder kit @Brake pad
@ Brake hose @) Pad spring
@ Brake pedal @Brake disc
BRAKE FLUID TYPE:
lONm(l.Om.kg,7.2ft-lb)
pNm(0.6
-1 m - kg, 4.3
.~
IEl USENEWONEI
%, & ,,/1 DI U S E NEW O N E ( R e p l a c e a s s e t ) J

A
/I/h”?@ , / 35 Nm (3.5 m-kg, 25 ft-lb) /
7-11
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary fO disarremble the brake
caliper and brake tlore to replace the brake pads.

FRONT AND REAR BRAKE piqzq

*
8 Inspect:
. Brake fl”,d level
refer to the “BRAKE FLUID INSPEC
TICIN” SeCtlo” I” the CHAPTER 3

(CHAS[ &if31
Caliper Bleed screw:

6 Nrn (0.6 m 4.3
18Nrn ,1.8rn’@L 13ft.b)

FRONT AND REAR BRAKE pi&q
CALIPER DISASSEMBLY
Before disassembling the front brake caliper or

rear brake caliper, drain the brake system of its
brake fluid.
Front Brake
1. Remove:
0 Cover
0 Retaining clips
0 Retaining pins
?? Pad spring
Refer to the “BRAKE PAD REPLACE

MENT” section.
2. Remove:
?? Brake hose @

3. Remove:
?? Caliper body
4. Remove:
@Pistons @
?? Dust seals @
0 Piston seals 0

I I 1
FRONT AND REAR BRAKE (CHASJ ebbI
Remove steps:
?? Blow compressed air into the tube joint
caliper body.

from the cylinder.
Rear Brake
1. Remove:
?? Brake hose @

2. Remove:
?? Retaining bolts @
?? Brake pads @
?? Pad spring
MENT” section.
3. Remove:
?? Piston @
?? Piston seal @
?? Dust seal @
7-17

Removal steps:
*Blow compressed air into the tube joint
caliper body.

from the cylinder.
MASTER CYLINDER DISASSEMBLY
NOTE:
master cylinders, drain the brake system of the
brake fluid.
Front Brake
1. Remove:
*Brake lever @
?? Brake switch @
2. Remove:
?? Union bolt @
?? Copper washer @
?? Brake hose @
7-18

I I I
FRONT AND REAR BRAKE (CHAS( &s?#&/

3. Remove:
@Screw (Master cylinder cap) @
?? Rubber seal @
?? Union bolt @
?? Copper washer @
?? Bolt (Master cylinder bracket) @

?? Master cylinder bracket 0
?? Master cylinder 8
?? Dust boot @
?? Circlip @
Rear Brake
1. Remove:
*Cotter pin @
?? Plain washer @
@Shaft @
?? Union bolt @
?? Copper washer @
?? Bolt (Master cylinder) @
@Adjusting rod @
aMaster cylinder kit @

1. Inspect:
@Caliper piston
Rust/Wear + Replace.
@Caliper cylinder body
7-19

I 1
2. Measure:
?? Brake pad thickness @

t 1 I
c&----k@
1 I I
Pad Wear Limit:
0.5 mm (0.02 in)
NOTE:
Replace the pads as a set if either is found to be
worn to the wear limit.
3. Inspect:
?? Brake hose
4. Inspect:
??Master cylinder body
Scratches/Wear + Replace.
NOTE:
Clean all passages with new brake fluid.
5. Inspect:
Scratches/Wear + Replace.
?? Front brake
a Rear brake
7-20

ASSEMBLY
?? All internal parts should be cleaned in new

brake fluid only.
?? Internal parts should be lubricated with brake
fluid when installed.
Brake Fluid:
DOT #4
I #3 can be used.
?? Replace the piston seals whenever a caliper is

disassembled.
Front Brake
1. Install:
0 Piston seals @
?? Dust seals @
@Pistons @
2. Install:
?? Brake pad
?? Pad spring
?? Retaining bolt
0 Retaining trip
MENT” section.
3. Install:
?? Brake caliper @

35 Nm (3.5 m - kg, 25 ft. lb)
7-21
f
FRONT AND REAR BRAKE (CHASI &‘&I
4. Install:
0 Circlip @
. Dust boot @
5. Install:
?? Master cylinder
NOTE:
Tighten first the upper bolt, then the lower
bolt.
Bolts (Master Cylinder Bracket):

9 Nm (0.9 me kg, 6.5 ft. lb) I
1
6. Install:
?? Brake hose @
?? Copper washers @
?? Union bolts @
Union Bolts:
26 Nm (2.6 rn. kg, 19 ft. lb)
,
f& Master cylinder

?? Brake caliper
When installing the brake hose to the caliper,

lightly touch the brake pipe @ with the projec-
tion @ on the caliper.
Always use new copper washers.
7. Install:
?? Brake switch @
?? Brake lever @
?? Spring @
NOTE:
Apply lithium soap base grease to pivot shaft of
brake lever.
7-22

FRONT AND REAR BRAKE piqq
8. Fill:
?? Brake fluid
Recommended Brake Fluid:

DOT#4
If DOT # 4 is not available,
# 3 can be used.
m. CAUTION:
?? Use only the designated quality brake fluid.

??Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemical
reaction and lead to poor performance.

9. Install:
?? Rubber seal @
Screws (Master Cylinder Cap) :

2 Nm (0.2 m - kg, 1.4 ft- lb) I
10. Air bleed:

?? Brake system
Refer to the “AIR BLEEDING” section
in the CHAPTER 3.
7-23

~CHAS~&~~
Il. Inspect:
Fluid level is under “LOWER” level line

@ --, Replenish.
Rear Brake
1. Install:
0 Piston seal 0
?? Dust seal @
0 Piston @
2. Install:
?? Brake caliper

35 Nm (3.5 m - kg, 25 ft. lb)
3. Install:
?? Brake pad
?? Pad spring
?? Retaining bolt

MENT” section.
7-24

4. Install:
?? Adjusting rod @
*Bolt (Master Cylinder) @

@Shaft @
?? Plain washer @
0 Cotter pin 0
Bolt (Master Cylinder):

20 Nm (2.0 m- kg, 14 ft. lb) I
B
7
5. Install:
?? Reservoir tank
6. Install:
?? Master cylinder assembly @
b&l Bolts (Master Cylinder Assembly):

35 Nm (3.5 m- kg, 25 ft- lb) I
7. Install:
?? Pin 0
?? Plain washer
?? Cotter pin @
B
7-25

8. Install:
?? Brake hose
?? Copper washers
?? Union bolts
Union Bolts:
26 Nm (2.6 m- kg, 19 ft- lb)
?? Master cylinder
?? Brake caliper
A CAUT1QN:
When installing the brake hose , lightly touch
the brake pipe @ with the prejections @I o n
the caliper and master cylinder.
Always use new copper washers.
9. Fill:
?? Brake fluid
A CAUTION:
7-26

FRONT AND REAR BRAKE pii@q

mixing fluids may result in a harmful chem-

ical reaction and lead to poor performance.
IO. Install:
?? Diaphragm @
aBush @
?? Reservoir tank cap @
11. Air bleed:

?? Brake system
Refer to the “AIR BLEEDING” section in

the CHAPTER 3.
12. Inspect:
Fluid level is under “LOWER” level line @

+ Repleriish.
7-27

FRONT FORK ICHASl ebbI
FRONT FORK
@ Cap bolt @ Damper rod @I Seal spacer
@ O-ring @ Oil lock piece @ Guide bushing
@ Collar @ Inner tube @Outer tube
@ Spring seat (@ Dust seal @Gasket
@ Fork spring @) Retaining clip @ Drain screw
@ Rebound spring @ Oil seal @Gasket
A FORK OIL (EACH):
CAPACITY:
I3 4 4 4 cm3
(15.6 imp oz, 15.0 US oz)
OIL LEVEL:
92 mm (3.62 in)
C From top of inner fork tube
Fully compression without
spring
123Nm (2.- --.
D GRADE:
Fork oil 10WT or equivalent /
-0 i0
I
h /7
20 Nm (2.0 m-kg, 14 ft.lb)
FORK SPRING FREE LENGTH:

E
408 mm (16.1 in)
7-28

FRONT FORK Icti~Sl &ii]
REMOVAL


2. Remove:
?? Front wheel
Refer to the “FRONT WHEEL - REMO-

VAL” section.
3. Remove:
?? Front brake caliper
?? Front fender @
?? Bolts (Brake hose clamp) @
4. Loosen:
?? Bolts (Handlebar bosses) @
5. Remove:
?? Handlebar (Right) @
?? Handlebar bosses (Left and right) @I with
handlebar (Left) @
6. Loosen:
?? Cap bolts @

FRONT FORK
7. Loosen:
?? Pinch bolt (Handlebar crown) @
?? Pinch bolt (Steering stem) @
B
Support the fork before loosening the pinch
bolts.
8. Remove:
?? Front fork
DISASSEMBLY
1. Remove:
*Cap bolt @
*Collar @
0 Spring seat @
?? Fork spring @
Drain the fork oil
2. Remove:
?? Dust seal @
0 Retaining clip @
Use a thin flat screwdriver, and be careful
not to scratch the inner fork tube.
3. Remove:
?? Bolt (Damper rod)
Use the Damper Rod Holder @ and

T-Handle @ to lock the damper rod.
7-30

FRONT FORK (cHns(f
4. Remove:
?? Damper rod @
?? Rebound spring @
5. Remove:
?? Inner tube
.
Inner tube removal steps:
?? Hold fork leg horizontally.
@Clamp the caliper mounting boss of the

outer tube securely in a vise with soft jaws.
?? Pull out the inner tube from the outer tube
by forcefully, but carefully, with drawing
the inner tube.
NOTE:
?? Excessive force will damage the oil seal
and/or the bushes. Damaged oil seal and
bushing must be replaced.
mAvoid bottoming the inner tube in the outer
tube during the above procedure, as the oil
lock piece will be damaged.
6. Remove:
??Oil seal @
??SeaI spacer @
@Guide bushing @
~Oil lock piece @
INSPECTION
1. Inspect:
?? Inner tube
Scratches/Bends --f Replace.
Do not attempt to straighten a bent inner fork

tube as this may dangerously weaken the tube.
7-31

FRONT FORK lons]l
2. Inspect:
?? Outer tube
Scratches/Bends/Damage + Replace.
3. Measure:
?? Fork spring
Over specified limit + Replace.
Fork Spring Free Length (Limit) @ :

408 mm (16.1 in)
1
4. I nspect :
?? Damper rod @
aRing @
Wear/Damage --f Replace.
Contamination + Blow out all oil passages
with compressed air.
?? 0il lock piece
?? O-ring (Cap bolt)
Damage + Replace.
ASSEMBLY
Before assembling, clean and inspect all parts
and replace when necessary.
NOTE:
In front fork assembly, be sure to use following
new parts. Do not reuse them.
?? Slide bushing
?? Guide bushing
0Oil seal
?? Dust seal
1. Install:
?? Rebound spring @
@Damper rod @
Allow the rod to slide slowly down the
tube until the it protrudes from the
bottom.
@Oil lock piece @
Fit oil lock piece over damper rod sticking
out of the inner tube.
?? Inner tube @
Into the outer tube.
7-32

FRONT FORK piq&q
2. Tighten:
?? Bolt (Damper rod)
Use the Damper Rod Holder @ and

T-Handle @ to lock the damper rod.
Bolt (Damper Rod):

40 Nm (4.0 m - kg, 29 ft. lb)
Apply LOCTITE @
3. Install:
?? Guide bushing @ (New)
Into the outer tube @ .

0Seal spacer @
On the top of guide bushing 0.
0Oil seal @
Use the Fork Seal Driver Weight @ and
Adopter @ .
?? Retaining clip
?? Dust seal
4. Fill:
?? Front fork
7-33

FRONT FORK piqiq
Each Fork:
444 cm3
(15.6 Imp oz, 15.0 US oz)
Fork Oil IOWT or equivalent
After filling, slowly pump the fork
up and down to distribute oil.
Oil Level @ :
92 mm (3.62 in)
From the top of inner fork tube
fully compressed without spring.
@ Inner tube
@ Fork oil
5. Install:
?? Fork spring
With the smaller pitch side up.

0 Spring seat
0 Collar
?? Cap bolt
Temporarily tighten the cap bolt.
23 Nm (2.3 m-kg, 17 ft. lb)
INSTALLATION
Reverse the removal procedure.
Note the following point.
1. Install:
?? Front fork
Temporary tighten the pinch bolts.
NOTE:
Hold the inner tube with its top 44 mm (1.7 in)
above the top of the handlebar crown.
7-34

FRONT FORK (CHASII

?? Pinch bolt (Steering stem) @
3. Install:
?? Handlebar boss
NOTE:
Insert the pin on the spacer into the correspond-
ing hole on the handlebar.
Bolts (Handlebar Boss) :

23 Nm (2.3 m-kg, 17 ft-lb) I
4. Install:
?? Front fender
Bolt (Front Fender):

7 Nm (0.7 m-kg, 5.1 ft. lb) I
5. Install:
?? Front wheel
Refer to the “ F R O N T W H E E L - I N
STALLATION” section.
Front Axle:
58 Nm (5.8 me kg, 42 ft. lb)
Bolts (Brake Caliper) :
35 Nm (3.5 rn- kg, 25 ft. lb)
Pinch Bolt (Front Fork):
20 Nm (2.0 rn- kg, 14 ft.lb)
Make sure that the brake hoses are routed

properly.
7-35

STEERING HEAD AND HANDLEBAR
Handlebar
@ Throttle guide tube 8 Locknut
@ Handlebar (Right) @ Adjuster
@ Handlebar boss (Right) @ Clutch cable
@ Handlebar boss (Left) @ Throttle cable 1
@ Handlebar (Left) @ Throttle cable 2
@ Grip rubber @I Starter cable
0 Handlebar grip end @ Starter lever assembly
23 Nm (2.3 m-kg, 17 ft-lb)
4
i 0
25 Nm (2.5 m-kg, 18 ft.lb)
7-36

Steering Head
@ Steering stem nut @ Ring nut (Lower)
@ Handle crown @Bearing cover
@ Lock washer @Bearing (Upper)
@ Ring nut (Upper) @ Bearing (Lower)
@ Washer @Steering stem
1 IlONm (11 m-ks.BOft-lb) 1
26 Nm (2.6 m*kg, 19 ft.lb)
IST:
52 Nm (5.2 m-kg, 37 ft.lb)
2ND:
A
LOOSEN IT COMPLETELY
3RD:
3 Nm (0.3 m-kg, 2.2 ft.lb)
7-37

REMOVAL


2. Remove:
?? Front wheel
Refer to the “FRONT WHEEL - RE-

MOVAL” section.
3. Remove:
?? Bracket (Master cylinder)
4. Remove:
?? Handlebar grip end (Right) @
5. Remove:
?? Handlebar switch (Right)

6. Remove:
?? Throttle cable 0
?? Handlebar grip (Right) @
7. Remove:
?? Handlebar switch (Left) @
8. Remove:
?? Handlebar grip end (Left) @
?? Handlebar grip (Left) @
?? Clutch lever holder @
9. Remove:
?? Handlebar (Right)
?? Handlebar bosses (Left and right) @ with
handlebar (Left).
10. Loosen:
11. Remove:
Refer to the “COWLING REMOVAL

12. Remove:
?? Front forks (Left and right)
Refer to the “ F R O N T F O R K - R E -
MOVAL” section.
7-39

STEERING HEAD AND HANDLEBAR piqq
13. Remove:
?? Horn @
?? Joint (Brake hose) @
14. Remove:
?? Handlebar crown
15. Remove:
?? Lock washer @
??Ring nut (Upper) @
Use Ring Nut Wrench
Ring Nut Wrench:

P/N Y U-33975
16. Remove:
?? Washer @
?? Ring nut (Lower) @
?? Bearing cover @
Support the steering shaft so that it may not fall

down.
17. Remove:
?? Steeringstem @
?? Bearing (Upper) @
?? Bearing (Lower)

INSPECTION
1. Wash the bearing in a solvent.
2. inspect:
?? Bearings
?? Bearing race
Pitting/Damage 4 Replace.
Bearing race remplacement steps:

?? Remove the bearing races using long rod @
and the hammer as shown.

?? Remove the bearing race on the steering
stem using the floor chisel @ and the ham-
mer as shown.
?? install the new dust seal and races.
NOTE:
Always replace bearings and races as a set.
3. Inspect:
?? Handlebars
Bents/Damage + Replace.
4. Inspect:
?? Handlebar bosses
Cracks/Damage + Replace
7-41

STEERING HEAD AND HANDLEBAR -1
INSTALLATION
1. Lubricate:
0 Bearings (Upper/Lower)
?? Bearing races
Lithium-Soap Base
2. Install:
??Bearing (Lower) @
Onto the steering stem.
0 Steering stem @
B CAUTION:
Hold the steering stem until it is secured.
@Bearing (Upper) @
?? Bearing cover @
?? Ring nut (Lower) @
3. Tighten:
?? Ring nuts (Lower/Upper)
Ring nuts tightening steps:
NOTE:
Set the Torque Wrench to the Ring Nut
Wrench so that they form a right angle.
?? Install the ring nut (Lower) @ .
NOTE:
ward.
?? Tighten the ring nut @ using the Ring Nut

Wrench.
Ring Nut Wrench:

P/N Y U-33975
Ring Nut 0 (Initial Tightening):

52 Nm (5.2 ma kg, 37 ft. lb)
.LOOSEN THE RING NUT @ COMPLETE-

LY and retighten it to specification.
Do not over-tightening.
Ring Nut @ (Final Tightening):

3 Nm (0.3 m-kg, 2.2 ft. lb)
7-42

STEERING HEAD AND HANDLEBAR lGi&&iJ
?? Check the steering stem by turning it lock to
lock. If there is any binding, remove the
steering stem assembly and inspect the steer-
ing bearings 0, 0.
?? Install the washer @ .
?? Install the ring nut (Upper) 0.
NOTE:
ward.
.FINGER TIGHTEN THE RING NUT 0 ,

then align the slots of both ring nuts. If not
aligned, hold the lower ring nut @ a n d
tighten the other until they are aligned.
?? Install the lock washer 8.
NOTE:
Make sure the lock washer tab is placed in the
slots.
?? Install the handle crown @ , and tighten

the steering stem nut @ to specification.
Nut (Steering Stem):

110 Nm (11.0 m-kg, 80 ft. lb)
4. Install:
?? Brake hose joint
Brake (Brake Hose Joint):

10 Nm (1.0 m- kg, 7.2 ft. lb) I
5. Install:
?? Front fork (Left and right)
Refer to the “FRONT FORK - INSTALL-

TION” section.
pii+jzJ Pinch Bolt (Handlebar Crown):
7-43

STEERING HEAD AND HANDLEBAR CHAS &b
8. Install:
?? Handlebar bosses
NOTE: -
Insert the pin on the handlebar bosses into the
corresponding hole on the handlebar crown.
9. Install:
?? Handlebars
Pinch Bolts (Handlebar):

23 Nm (2.3 m-kg- 17 ft.lb) I
10. Install:
*Clutch lever holder @
?? Handlebar switch (Left) @
?? Handlebar grip (Left) @
?? Handlebar grip end (Left) @
Handlebar (Left) installation steps:

?? Install the lever holder with the punched
mark @ on the handlebar aligning with the
slit in the lever holder @ .
Bolt (Lever Holder) :

10 Nm (1.0 rn- kg, 7.2 ft. lb)
?? Install the handlebar switch (Left)
@Apply align coat of an adhesive for rubber

to the handlebar end, as shown.
@20 mm (0.8 in)
?? Fit the handlebar grip fully over the handle-
bar end.
Leave the handlebar intact until the adhesive
I becomes dry enough to make the grip and

handlebar stuck securelv.

?? Install the handlebar grip end (Left)
11. Install:
?? Handlebar grip (Right)
?? Throttle cable
?? Handlebar switch (Right)
NOTE:
Before installing the handlebar grip (Right),
apply a light coat of lithium soap base grease
onto the handlebar end.
12. Install:
?? Front brake master cylinder
NOTE:
Install the master cylinder with the punched
mark @ on the handlebar aligning with the
master cylinder end 0.
Bolts (Master Cylinder Bracket):

9 Nm (0.9 m - kg, 6.5 ft. lb) I
13. Install:
?? Handlebar grip end (Right) @
Provide a clearance of 1 mm (0.04 in) between

the handlebar grip @ and the handlebar grip
end @ . Otherwise, the grip may not move.
Handlebar Grip End:

25 Nm (2.5 m-kg, 18 ft- lb) I
7-45

STEERING HEAD AND HANDLEBAR CHAS &b
14. Install:
?? Front fender
Bolt (Front Fender) :

7 Nm (0.7 m-kg, 5.1 ft-lb) I
15. Install:
/
?? Front wheel
Refer to the “FRONT WHEEL - INSTA-

LLATION” section.
P
Wheel Axle:
58 Nm (5.8 m-kg, 42 ft. lb)
Bolt (Brake Caliper):
35 Nm (3.5 m - kg, 25 ft. lb)
Pinch Bolt (Front Fork):
20 Nm (2.0 m-kg, 14 ft- lb)
16. Install:
?? Clutch cable
NOTE:
Apply a light coat of lithium soap base grease
onto the clutch cable end.
17. Adjust
?? Clutch cable free play
Refer to the “CLUTCH ADJUSTMENT”

7-46

REAR SHOCK ABSORBER AND SWINGARM
Rear Shock Absorber
@ Shock absorber
@ Collar
@ Washer
@ Collar
@ Oil seal
@ Bearing

Swingarm
@ Swingarm @ Guard seal NOTE:
@ Bearing @ Arm (Left) Coat the bearings, bushings, thrust covers, oil seals, and
@ Thrust washer @ Arm (Right) collars with a liberal amount of light weight lithiun-soap
@ Thrust cover C@ Oil seal base grease before installing. After installing, thoroughly
0 Bush @ Collar wipe off excess grease.
@ Pivot shaft @ Relay arm
/7$&40 NmgO m-kg, 29 ft.lb)]
h-Tx p>40 Nm (4.0 m-kg, 29 ft.lb) 1
SIDE PLAY (AT END OF SWING ARM):

1 .O mm (0.04 in)
7-48

REAR SHOCK ABSORBER AND SWINGARM ICHAS( &I
HANDLING NOTES
This shock absorber contains highly compressed

nitrogen gas. Read and understand the following
information before handling the shock absorber.
The manufacturer cannot be held responsible for
property damage or personal injury that may
result from improper handling.
1. Do not tamper or attempt to open the
cylinder assembly.
2. Do not subject shock absorber to an open
flame or other high heat. This may cause the
unit to explode due to excessive gas pressure.
3. Do not deform or damage the cylinder in
any way. Cylinder damage will result in
poor damping performance.
DISPOSAL NOTES
2 5 - 30 mm
(l.O- 1 . 2 i n )
Shock absorber disposal steps:
Gas pressure must be released before dispos-
ing the shock absorber. To do so, drill @ a
2 - 3 mm (0.08 - 0.12 in) hole through the
cylinder wall at a point 25 - 30 mm (1.0 -
1.2 in) under the spring seat.
Wear eye protection to prevent eye damage

from escaping gas and/or metal chips.
REMOVAL
Rear Shock Absorber

7-49

2. Remove:
in the CHAPTER 3.
3. Remove:
?? Bolt (Arms - Bottom)
4. Remove:
?? Bolt (Swingarm) @
?? Bolt (Rear shock absorber - Bottom) @
?? Relay arm @
5. Remove:
?? Bolt (Rear shock absorber - Top) @
?? Rear shock absorber @
Swingarm

danger of it falling down.
7-50

ICI
HASI &I
1. Remove:
?? Rear wheel
Refer to the “ R E A R W H E E L - R E -
MOVAL” section.
?? Rear shock absorber
2. Remove:
?? Chain case
3. Check:
*Swingarm (Side play) @
Side play + Replace the bearings and collar.
Move the swingarm from side to side.
There should be no noticeable side play.
Side Play (At End of Swingarm):

1.0 mm (0.04 in)
4. Check:
?? Swingarm (Vertical movement) @
Tightness/Binding/Rough spots + Replace
the bearings.
Move the swingarm up and down.

‘,, ” 6. Remove:
?? Guard seal
7. Remove:
?? Tension bar
8. Remove:
?? Arms (Left and right)
9. Remove:
?? Thrust covers @
aThrust washer @
@Bush @
INSPECTION
Rear shock absorber
1. Inspect:
?? Rear shock absorber
Oil leaks/Damage -+ Replace.
7-52

REAR SHOCK ABSORBER AND SWINGAF ,, 3M lcHAsl &b
Swingarm
1. Wash the bearings in a SOlVent.
2. Inspect:
?? Bearings (Race/Rollers) @
Pitting/Damage + Replace.
?? Trust washers @
?? Trust covers @
Damage + Replace.
?? Collar @
?? Pivot
shaft
Damage + Replace.
3. Inspect:
?? Arm (Left) @
*Arm (Right) @
?? Relay arm @
Damage + Replace.
?? Bearings
Pitting/Damge + Replace.
0Oil seals
?? Collars
Damage --f Replace.
7-53

REAR SHOCK ABSORBER AND SWINGARM -1
INSTALLATION
1. Lubricate:
?? Bearings
0 Oil seals
0 Collars
Lithium-Soap Base Grease
Swingarm
1. Install:
@Guard seal @
@Tension bar @
Screw (Guard Seal):

8 Nm (0.8 m - kg, 5.8 ft- lb)
A
t Bolt (Tension Bar):
I 15‘Nm (1.5 m- kg, 11 ft. lb)
2. Install:
@Arms (Left and right) @
Bolt (Arm) :
40 Nm (4.0 m-kg, 29 ft. lb) I
3. Install:
?? Swing arm @
Pivot Shaft (Swingarm):

90 Nm (9.0 m- kg, 65 ft. lb)
Rear Shock Absorber

1. Install:
?? Rear shock absorber @
Rear Shock Absorber:

Upper:
40 Nm (4.0 rn- kg, 29 ft. lb)
7-54

REAR SHOCK ABSORBER AND SWINGARM pi&q
2. Install:
?? Relay arm @
Rear Arm - Frame:

40 Nm (4.0 me kg, 29 ft- lb)
Relay Arm - Rear Shock Absorber:
40 Nm (4.0 m - kg, 29 ft. lb)
3. Install:
?? Arms (Left and right) @
Relay Arm - Arms:

40 Nm (4.0 m s kg, 29 ft. lb)
4. Install:
?? Rear wheel
Refer to the “REAR WHEEL - INSTAL-

LATION” section.
Nut (Rear Axle):

107 Nm (10.7 rn. kg, 77 ft. lb)
35 Nm (3.5 rn. kg, 25 ft. lb)
5. Adjust:
Refer to the “DRIVE CHAIN SLACK

ADJUSTMENT” section in the CHAPTER
Drive Chain Slack:

10 - 20 mm (0.4 - 0.8 in)
-55

DRIVE CHAIN AND SPROCKET piiqziq
DRIVE CHAIN AND SPROCKET
REMOVAL
1, Place the motorcycle verticaly on a level
place.

2. Remove:
aShift arm
?? Nut (Drive sprocket)
?? Lock washer
?? Drive sprocket
Refer to the “ENGINE - REMOVAL”

3. Remove:
?? Rear wheel
?? Swingarm
o Drive chain
Refer to the “ R E A R W H E E L -. R E -
MOVAL” and REAR SHOCK ABSORBER
AND SWINGARM - REMOVAL”.
4. Remove:
?? Driven sprocket
INSPECTION AND CLEANING

1. Measure:
?? Drive chain wear @
Length of 10 links.
Over specified limit + Replace the drive
chain, drive sprocket and driven sprocket
as a set.
Drive Chain Wear Limit (10 Links):

150.1 mm (5.91 in)
7-56

DRIVE CHAIN AND SPROCKET (CHASI&(
2. Check:
?? Drive chain stiffness
Clean and oil the chain and hold as illus-

trated.
Stiff + Replace drive chain.
3. Clean:
?? Drive chain
Drive Chain Cleaner:

Kerosene
A CAWTIUM:
Do not use steam cleaning, high-pressure hashes,
and certain solvent of O-ring @ damage may
occur.
4. Inspect:
0 ?? Drive sprocket
‘/-.@
\\
More than l/4 teeth @ wear --f Replace
\ ‘. II sprocket.
\
A
0 OC orrect
@ Roller
w-014
@Sprocket
5. Inspect:
?? Drive sprocket
Bent teeth @ --f Replace sprocket.
@Slip off
INSTALLATION
1. Install:
?? Driven sprocket
Nuts (Driven Sprocket):

32 Nm (3.2 mm kg, 23 ft. lb)
7-57

DRIVE CHAIN AND SPROCKET pii&J
2. Lubricate:
?? Bearings
0 Oil seals
?? Collars
Lithium-Soap Base Grease
3. Install:
?? Drive chain
0 Swingarm
?? Rear wheel
Refer to the “REAR SHOCK ABSORBER

A N D SWINGARM - I N S T A L L A T I O N ”
and “REAR - WHEEL - INSTALLA-
TION”.
4. Install:
?? Drive sprocket
?? Lock washer (New)
?? Nut (Drive sprocket)
Nut (Drive Sprocket):

70 Nm (7.0 ma kg, 50 ft. lb)
5. Install:
?? Shift arm
6. Adjust:
Refer to the “ D R I V E C H A I N S L A C K
ADJUSTMENT” section in the CHAPTER
Drive Chain Slack:

10 - 20 mm (0.4 - 0.8 in)
.A CAWlON :
Too small chain slack will overload the engine
and other vital parts; keep the slack within the
specified limits.
7-58

CIRCUIT DIAGRAM wELEC(
ELECTRICAL
FZR400WSUC CIRCUIT DIAGRAM
,,q B
6
L Ch
@
B B B
IL A
8-l

CIRCUIT DIAGRAM \ELECl
m]
@ Main switch @? Starting circuit cut-off relay
@ Rectifier/Regulator @ Flasher relay
@ A.C. generator @ Cancelling unit
@ “START” switch @ “TURN” switch
@ Starter motor @ “TURN” indicator light
@ Starter relay @ Front position light/Flasher light (Left)
@ Fuse “MAIN” @ Rear flasher light (Left)
@ Battery @ Rear flasher light (Right)
@ Fuse “IGNITION” @ Front position light/Flasher light (Right)
@ “ENGINE STOP” switch @ Reed switch
@ Diode block @ Horn
@I Clutch switch @? “HORN” switch
@ Sidestand switch @ Tachometer
@ Ignition circuit cut-off relay @ Temp meter
@ Digital ignitor unit @ Therm0 unit
@ Ignition coil (#l and #4 cylinder) @ Fuel pump relay
@ Ignition coil (#2 and #3 cylinder) @I Fuel pump
@ Pickup coil @ Fuse “HEAD”
@ Spark plug @? “LIGHTS” (Dimmer) switch
@ Fuse “FAN” @ Meter light
@ Therm0 switch @ “HIGH BEAM” indicator light
@ Fan motor @ Headlight
@ Fuse “SIGNAL” @ Tail/Brake light
@ Front brake switch @ License light
@ Rear brake switch @I EXUP control unit
@ “NEUTRAL” indicator light @ EXUP servomotor
@,) Neutral switch
@ “01 L” indicator light ?? For California only
@ Resistor
@! Oil level switch
@ Relay assembly
COLOR CODE
0 Orange Y/R Yellow/Red
R Red Br/W Brown/White
L Blue R/W Red/White
Br Brown R/Y Red/Yellow

-
B Black B/R Black/Red
-
Y Yellow B/W Black/White
-.
W White B/Y Black/Yellow
G Green L/W Blue/White
P Pink L/B Blue/Black
DC3 Dark green L/Y Blue/Yellow
Ch Chocolate G/Y Green/Yellow
Gray W/R White/Red

GY
Sb Sky blue WIG White/Green
B-2

ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS (1)
@Therm0 switch @ Sidestand relay
@ T h ermo unit @ EXUP control unit
@ Relay assembly (For California only)
@ Fuel pump relay $j) EXUP ServOmOtOr
@Horn (For California only)
@Oil level switch
@ Neutral switch
@ Sidestand switch
8-3

ELECTRICAL COMPONENTS
\ELEC( m]
ELECTRICAL COMPONENTS (2)

@ Wireharness @Battery
@ Rear brake switch @Starter relay
@ Diode block @Rectifier/Regulator
@Fuse “MAIN” @Digital ignitor unit
@Main switch
@Ignition coil
@Plug cap
\I I” 112V,RAH
B-4

CHECKING OF SWITCHES IELECI Eii I
CHECKING OF SWITCHES
Check the switches for the continuity between
the terminals to determine correct connection.
Read the following for switch inspection.
SWITCH CONNECTION AS SHOWN IN

MANUAL
The manual contains a connection chart as shown
left showing the terminal connections of the
switches (e.g., main switch, handlebar switch,
brake switch, lighting switch, etc.)
The extreme left column indicates the switch po-

sitions and the top line indicates the colors of
leads connected with the terminals in the switch
component.
“C’&-0” indicates the terminals between which

there is a continuity of electricity; i.e., a cl.osed
circuit at the respective switch positions.
In this chart:
“R and Br” and “L/W and L/R” are continuous
with the “ON” switch position.
“B and B/W” is continuous with the “OFF”

switch position.
“B and B/W” is continuous with the “LOCK”

switch position.
“B and B/W” and “R and L/R” are continuous

with the “P” switch position.
CHECKING SWITCH FOR TERMINAL

CONNECTION
Before checking the switch, refer to the connec-
tion chart as shown above and check for the cor-
rect terminal connection (closed circuit) by the
color combination.
To explain how to check the switch, the main

switch is taken for example in the following.
8-5

CHECKING OF SWITCHES
_I-
1. Disconnect the main switch coupler from the
wireharness.
Never disconnect the main switch coupler

by pulling the leads. Otherwise, leads may
be pulled off the terminals inside the coupler.
2. Inspect whether any lead is off the terminal

inside the coupler. If it is, repair it.
NOTE:
If the coupler is clogged with mud or dust, blow
it off by compressed air.
3. Use the connection chart to check the color

combination for continuity (a closed circuit).
In this example, the continuity is as follows.
“R and Br” and “L/W and L/R” are continu-

ous with the “ON” switch position.
“B and B/W” is continuous with the “OFF”

switch position.
“B and B/W” is continuous with the “LOCK”

switch position.
“B and B/W” and “R and L/R” are continu-

ous with the “P” switch position.
Please note that there is no continuity (an

open circuit) at all for the color combinations
other than the above.
4. Check the switch component for the continui

ty between “R and Br”.
Checking steps:
?? Turn the switch key to the “ON”, “OFF”,
“LOCK”, and “P” several times.
*Set the pocket tester selector to the ‘9 x 1”.
aConnect the tester ( + ) lead to the “R” lead
terminal in the coupler and the ( - 1 lead to
the “Br” lead terminal.
8-6

CHECKING OF SWITCHES IiL-iii~
NOTE:
Use thin probes for checking the continuity.
Otherwise, the probes may contact other ter--
minals inside the coupler.
*Check the continuity between “R” and “Br”

at the respective switch positions of “ON”
0, “OFF” 0, “LOCK” 0, and “P” 0.
There must be continuity (the tester indicat--
ing “0”) at the “ON” switch position, and
there must be no continuity (the tester indicat-
ing “oo’l) at “OFF”, “LOCK”, or “PI’. There
is something wrong between “R” and “Br”
if there is no continuity at the “‘ON” position
or if there is some continuity either at the
“OFF” or “LOCK” or “P”.
NOTE:
Check the switch for continuity several times.
5. Next go on to checking of the continuity be-

tween “B and B/W”, “L/W and L/R”, and
“R and L/R” at the respective switch posi-
tions, as in the same manner mentioned
above.
6. If there is something wrong with any one of

the combinations, replace the switch com-
ponent.
8-7

CHECKING OF BULBS -1
CHECKING OF BULBS (FOR

HEADLIGHT, TAIL/BRAKE
LIGHT, FLASHER LIGHT, METER
LIGHT, ETC.)
Check the bulb terminal continuity for the condi-
tion of the bulb.
KINDS OF BULBS
The bulbs used in the motorcycle are classified
as shown left by the shape of the bulb socket.
@ and @ are mainly used for the headlight.
0 is mainly used for the flasher light and

tail/brake light.
0 and @are mainly used for the meter light and

other indicator lights.
CHECKING BULB CONDITION

1. Remove the bulb.
NOTE:
*Bulbs of the @ and @type uses a bulb holder.
Remove the bulb holder before removing the
bulb itself. Most of the bulb holders for this type
can be removed by turning them counter-
clockwise.
*Most of the bulbs of 0 and 0 type can be re-
moved from the bulb sockets by pushing and
turning them counterclockwise.
*Bulbs of the @type can be removed from the
bulb sockets by simply pulling them out.
Be sure to hold the socket firmly when

removing the bulb. Never pull the lead.
Otherwise, the lead may be pulled off the ter-
minal in the coupler.
Keep flammable products or your hands

away from the headlight bulb while it is on.
It will be hot. Do not touch the bulb until it
cools down.
8-8

CHECKING OF BULBS ITiETiil
2. Check the bulb terminals for continuity.
Checking steps:
*Set the pocket tester selector to the “Q x 1”.
*Connect the tester leads to the respective bulb
terminals. Take for example a 3-terminal bulb
as shown left. First check the continuity be-
tween the @ and @ terminals by connect-
ing the tester ( + 1 lead to the @ terminal and
the tester ( - ) lead to the @ terminal. Then
check the continuity between the @ and @
terminals by connecting the tester ( + ) lead
still to the @ terminal and the tester ( - 1lead
to the @ terminal. If the tester shows “a”
in either case, replace the bulb.
3. Check the bulb socket by installing a proven

bulb to it. As in the checking of bulbs, con-
nect the pocket tester leads to the respective
leads of the socket and check for continuity
in the same manner as mentioned above.
I
8-9

IGNITION SYSTEM (ELECII
IGNITION SYSTEM
CIRCUIT DIAGRAM
8-11

IGNITION SYSTEM
Aforementioned circuit diagram shows the ignition circuit in the wiring diagram.
NOTE:
For the color codes, see page 8-2.
@ Main switch
@ Fuse “MAIN”
@ Battery
@ Fuse “IGNITION”
@ “ENGINE STOP” switch
@Diode block
@ Sidestand switch
@ Sidestand relay
@ Digital ignitor unit
@ Ignition coil (#I and #4 cylinder)
@ Ignition coil (#2 and #3 cylinder)
@ Pickup coil
@ Spark plug
@ Neutral switch
8-12
.
IGNITION SYSTEM (ELECII
DIGITAL IGNITION CONTROL SYSTEM
DESCRIPTION
The electronic ignition that sparks the engine is
computer controlled and operated by the digital
microprocessor. It has a pre-programed ignition
advance curve.
This programed advance curve closely matches
the spark timing to the engine’s ignition require-
I ments. Only one pickup coil is needed to meet
t i
I
the requirements of the digital ignitor unit.
The digital ignitor also includes the control
unit for the electric fuel pump.
F--
II
[a Pickup coil
m Wave-shape shaping circuit
a Edge detection circuit
DJ Latch circuit
z Microprocessor
Lj Free-running counter
[G] Comparison circuit
La R e g i s t e r
[Tl Flip-flop circuit
[JJ Driving circuit
[KJ Ignition coil
71 Digital ignitor unit
OPERATION
The following operations are digitally-performed
by signal from the pickup coil signal:
1. Determing proper ignition timing.
2. Sensing the engine revolution speed.
3. Determing timing for switching on ignition
coil (duty control).
4. Increasing ignition coil primary current for
starting the engine.
5. Sensing engine stall.
6. Preventing over-revolution of the engine.
8-13

r
IGNITION SYSTEM
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE

(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check;
1. Fuse “MAIN” 8. “ENGINE STOP” switch
2. Battery 9. Neutral switch
3. Spark plug 10. Sidestand switch
4. Ignition spark gap 11. Sidestand relay
5. Spark plug cap resistance 12. Pickup coil resistance
6. Ignition coil resistance 13. Wiring connection
7. Main switch (Entire ignition system)
NOTE:
?? Remove the following before troubleshooting.
1) Seat 4) Top cover
2) Lower cowling 5) Air filter case
3) Center cowling 6) Crankcase cover (Left)
?? Use the following special tools in this troubleshooting.
Dynamic Spark Tester: Pocket Tester:

P/N. Y M-34487 P/N. YU-03112
1. Fuse “MAIN” NON CONTINUITY

??Remove the fuse “MAIN”.
?? Connect the Pocket Tester (fi x 1) to the
fuse “MAIN”.
?? Check the fuse “MAIN” for continuity. Replace fuse “MAIN”.
I
CONTINUITY
8 +
2. Battery INCORRECT
??Check the battery condition.
Refer to the “BATTERY INSPECTION”
r
Specific Gravity:
1.280 at 20°C (68” F)
n
& *
CORRECT
8-14

IGNITION SYSTEM IELECl liiiiil 1
a
*
3. Spark plug
*Check the spark plug condition.
Check the spark type.
??
@Check the spark plug gap.

Refer to the “SPARK PLUG INSPECTION”
INCORRECT
Standard Spark Plug:
I
CR8E (NGK), U24ESR-N (N.D.)
Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.032 in) I Repair or replace spark plug.
I
a
A
CORRECT
4. Ignition spark gap

*Disconnect the spark plug cap from spark
plug.
@Connect the Dynamic Spark Tester @ as
shown.
3 Spark plug cap
3 Spark plug
@Turn the main switch to “ON”.
?? Check the ignition spark gap.

BStart engine, and increase spark gap until MEETS SPECIFICATION
misfire occurs.
7
Minimum Spark Gap:
6.0 mm (0.24 in) I Ignition system is good.
I
OUT OF SPECIFICATION
OR NO SPARK
*
8-15

IGNITION SYSTEM -1
5. Spark plug cap resistance

?? Remove the spark plug cap.
?? Connect the Pocket Tester (n x 1 k) to the
spark plug cap.
@Check the spark plug cap for specificated
resistance.
r-II
a
63.
Spark Plug Cap Resistance:
9 - 11 kR at 20°C (68°F) Replace spark plug cap.
a
6. Ignition coil resistance
MEETS
SPECIFICATION
@Disconnect the ignition coil coupler from

the wireharness.
@Connect the Pocket Tester (SL x 1) to the
ignition coil.
Ignition coil (Right) @ : Ignition coil (Left) @ :

Tester (+) lead + Red/White @ Terminal Tester (+) lead --f Red/White @ Terminal
Tester (-) lead + Gray @ Terminal
?? Check the primary coil for specificated

resistance.
Primary Coil Resistance:

1.8 - 2.2n at 20°C (68” F)
8-16

IGNITION SYSTEM I=( Ed [
@Connect the Pocket Tester (0 x lk) to the

ignition coil.
Tester (+I Lead + Spark Plug Lead @

Tester (-) Lead + Spark Plug Lead @
?? Check the Secondary coil for specificated

resistance.
m Secondary Coil Resistance:

c-8:l
9.6 - 14.4 kR at 20°C (68” F)
(Spark Plug Lead - Spark plug) I Replace ignition coil.
I
BOTH MEET
SPECIFICATIONS
a
7. Main switch
*Disconnect the main switch coupler from
the wire harness.
?? Check the switch component for the conti-
nuity between “Red @ a n d B r o w n @ ‘I.
Refer to the “CHEKING OF SWITCHES”
section.
INCORRECT
I Replace main switch. I
CORRECT
*
8-17

IGNITION SYSTEM pqiq
8. “ENGINE STOP” switch

) Disconnect the “ENGINE STOP” switch
coupler from the wire harness.
~Check the switch component for the conti-
nuity between “Red/White @ and Red/-
White @ “. Refer to the “CHECKING OF
SWITCHES” section.
INCORRECT
I Replace handlebar switch (Right). I
CORRECT
a
9. Neutral switch
?? Disconnect the neutral switch coupler from
the wire harness.
nuity between ‘Sky blue @ and Ground”.
Refer to the “CHECKING OF SWITCHES”
section.
INCORRECT
Replace neutral switch.
CORRECT
8-18

IGNITION SYSTEM
*
10. Sidestand switch

n
B Disconnect the sidestand switch coupler
from the wire harness.
nuity between “Blue/Yellow @,? and Black
@ “. R e f e r t o t h e “ C H E C K I N G O F
INCORRECT
Replace sidestand switch. I
& CORRECT
Il. Sidestand relay
B Disconnect the sidestand relay coupler from

the wire harness.
BConnect the Pocket Tester (a x 1) and
battery (12V) voltage to the sidestand relay
coupler terminals.
Tester (+) Lead + Red/White @ Terminal

Tester (-) Lead --f Black @ Terminal
Battery (+) Lead --f Red/White @ Terminal
Battery (-) Lead --f Blue/Yellow @
Terminal
NOCONTINUITY
)Check the relay for continuity. 1 Replace sidestand relay.
a *
CONTINUITY
8-19

IGNITION SYSTEM (ELECI
*
a q
12. Pickup coil resistance
?? Disconnect the A.C. magneto Coupler from
the wire harness.
?? Connect the Pocket Tester (!2 x 100) to the
pickup coil terminal.
Tester (+) Lead + White/Red @Terminal

Tester (-) Lead + White/Black @ Terminal
@Check the pickup coil for specificated

resistance. OUT OF SPECIFICATION
Pickup Coil Resistance:

85 - 11551 at 20°C (68°F)
(White/Red -White/Black) I Replace pickup coil. I
v
-
MEET SPECIFICATION
POOR CONNECTION
lYKi7Yconnection
Check the entire ignition system for con-
4
[1 nections.
Refer to the “WI RING DIAGRAM”
1 section. Correct.
I
l-l
CORRECT
Digital ignitor unit is faulty. I

Replace the digital ignitor unit.
8-20

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
8-21

IELEC~ @i/ii
A forementioned circuit diagram shows the electric starting circuit in the wiring diagram.
NOTE:
@Main switch
@ “START” switch
@Starter motor
@Starter relay
@ Fuse “MAIN”
@ Battery
@Fuse “IGNITION”
(@ Diode block
@Clutch switch
@Sidestand switch
@Neutral switch
@Starting circuit cut-off relay (Relay assembly @ )
8-22

ELECTRIC STARTING SYSTEM -1
STARTING CIRCUIT OPERATION
The starting circuit on this model consist of the
starter motor, starter relay, and the relay unit
(starting circuit cut-off relay). If the engine stop
switch and the main switch are both closed, the
starter motor can operate only if:
The transmission is in neutral (the neutral

switch is closed).
II
0 j.
or if
The clutch lever is pulled to the handlebar

0 M
- r (the clutch switch is closed) and the sidestand
is up (the sidestand switch is closed.)
I
The starting circuit cut-off relay prevents the

starter from operating when neither of these
conditions has been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor.
When one of both of the above conditions have

been met, however, the starting circuit cut-off
relay is closed, and the engine can be started by
1
pressing the starter switch.
w WHEN THE TRANSMISSION IS IN

NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED IN
@Battery
OS tarter motor
@Starter relay
@Main switch
@“ENGINE STOP”switch
@Starting circuit cut-off relay
@ ‘START” switch
@Neutral switch
@Clutch switch
@ Sidestand switch
@ T 1gnl ‘t’Ion circuit cut-off relay

0
8-23

ELECTRIC STARTING SYSTEM pEpq
TROUBLESHOOTING
I STARTER MOTOR DOES NOT OPERATE.

1
Procedure
Check;
1. Fuse “MAIN” 8. Neutral switch
2. Battery 9. Sidestand switch
3. Starter motor 10. Clutch switch
4. Starter relay 11. “START” switch
5. Starting circuit cut-off relay 12. Wiring connection
6. Main switch (Entire electric starting system)
NOTE:
Remove the following before troubleshooting.
1) Seat 3) Lower cowling
2) Seat cowling 4) Fuel tank
?? Use the following special tool in this troubleshooting.
Pocket Tester:
P/N. YU-03112
1. Fuse “MAIN” NON CONTINUITY

?? Remove the fuse “MAIN”.
?? Connect the Pocket Tester (s2 x 1) to the
1
fuse “MAIN”.
l-l
*Check the fuse “MAIN” for continuity.
CONTINUITY
Replace fuse “MAIN”.
Check the battery condition.
Specific Gravity:
1.280 at 20” C (68” F 1
CORRECT
-(1
*
8-24

ELECTRIC STARTING SYSTEM p-p@
3. Starter motor
BConnect the battery positive terminal @
and starter motor cable @ using the jumper
lead @ * as shown. @A wire for the jumper lead must have
the equivalent capacity as that of the
battery lead or more, otherwise it may
cause the jumper lead to be burned.
aThis check is likely to produce sparks,
so be sure that no flammable gas or
fluid is in the vicinity.
NO OPERATIVE
Y 7
)Check the starter motor operation. Repair or replace starter motor.

I
OPERATIVE
4. Starter relay
?? Disconnect the starter relay lead.
?? Ground the starter relay lead @ to the
frame using the jumper lead @ as shown.
=
-
z
I NO OPERATIVE
D Check the starter motor operation. r--~

Replace starter relay. I
OPERATIVE
a
5. Starting circuit cut-off relay
?? Disconnect the relay assembly coupler from
the wire harness.
?? Connect the pocket tester (a x 1) and
battery (12V) voltage to the relay assembly
coupler terminals.
I
8-25

Tester (+) Lead + Red/White @ Terminal

Tester (-) Lead+ Black/Yellow @ Terminal
Tester (+) Lead + Blue/White @ Terminal
Tester (-) Lead-+ Blue/White @ Terminal
NO CONTINUITY
I
??Check the starting circuit cut-off relay for

Replace relay assembly.
1 continuity.
a
m
CONTINUITY
6. Main switch
?? Disconnect the main switch coupler and
lead from the wire harness.
nuity between “Red @ and Brown @ “.
section.
INCORRECT
Replace main switch.
v
CORRECT
??Disconnect the “ENG I NE STOP” switch

nuity between “Red/White @ and Red/-
8-26

INCORRECT
Replace handlebar switch (Right).

1
4L
\-
CORRECT
8. Neutral switch
the wire harness.
nuity between “Sky blue @ and Ground”.
section.
INCORRECT
I Replace neutral switch. 1

CORRECT
a
9. Sidestand switch
B Disconnect the sidestand switch coupler
nuity between “Blue/Yellow @ and Black
0 “. Refer to the “CHECKING OF
INCORRECT
I Replace sidestand switch. 1

v CORRECT
8-27

* ELECTRIC STARTING SYSTEM -1
10. Clutch switch

a
?? Disconnect the clutch switch coupler from
wire harness.
@Check the switch component for the conti-
nuity between “Blue/Yellow @ and Black/-
Yellow @ “. Refer to the “CHECKING OF
INCORRECT
I
Replace clutch switch.

d
,CORRECT
11. “START” switch

@Disconnect the “START” switch coupler
from wire harness.
@Check t h e “START” switch component
for the continuity between “Blue/White
@ a n d B l a c k 0. I’. Refer to the “CHECK-
ING OF SWITCHES” section.
INCORRECT
Replace handlebar switch (Right).

I
CORRECT
I POOR CONNECTION
12. Wiring connection
Check the entire ignition system for connec-
tions.
Refer to the “WIRING DIAGRAM” section. IC orrect. I
a
L
OK
8-28

*
I Diode block is faulty.

Replace the diode block. I
8-29

STARTER MOTOR
@Brush
@Armature
@ Stator
@ O-ring
11.01
8-30

Removal
1. Remove:
?? Starter motor
Refer to the “ENGINE OVERHAUL -

ENGINE REMOVAL” section in the
CHAPTER 4.
Inspection and Repair

1. Inspect:
0 Commutator
Dirty + Clean it with #600 grit sandpaper.
2. Measure:
?? Commutator diameter @
Out of specification -+ Replace starter

motor.
Commutator Wear Limit @ :

22 mm (0.87 in)
3. Measure:
?? Mica undercut @
Out of specification + Scrape the mica to

proper value use a hacksaw blade can be
ground to fit.
Mica Undercut @ :
1.8 mm (0.07 in)
NOTE:
The mica insulation of the commutator must
be undercut to ensure proper operation of
commutator.
1 MR or more 052 4. Inspect:

*Armature coil (insulation/continuity)
Defects(s) --f Replace starter motor.
Armature coil inspecting steps:

?? Connect the Pocket Tester for continuity
check @ and insulation check 0.
??Measure the armautre resistances.
8-31

F
Armature Coil Resistance:

5f
cl Continuity Check @ :
0~2 at 20°C (68” F)
Insulation Check @ :
More than 1MR at 20°C (68°F)
?? If the resistance is incorrect, replace the
starter motor.
5. Measure:
?? Brush length @
Out of specification --f Replace.
Brush Length Limit:

5.0 mm (0.20 in)
6. Measure:
?? Brush spring pressure
Fatigue/Out of specification + Replace as a

set.
Brush Spring Pressure:

540 - 660 g (19.05 - 23.28 04
7. Inspect:
?? Bearing
0 Oil seal
00.rings @
Installation
1. Install:
0 Starter motor
NOTE :
Align the match marks @ on the bracket with
the match marks @ on the housing.
a-32

CHARGING SYSTEM -1
CHARGING SYSTEM
CIRCUIT DIAGRAM
I ! R/W1
tDm t
8-33

CHARGING SYSTEM IELEC\ @ii/ 1
Aforementioned circuit diagram show the charging circuit in the wiring diagram.
NOTE:
@ Rectifier/Regulator
@AC. generator
@ Fuse “MA IN”
@Battery
8-34

CHARGING SYSTEM -1
TROUBLESHOOTING
I THE BATTERY IS NOT CHARGED.
Procedure
Check;
1. Fuse “MAIN” 4. Stator coil resistance
2. Battery 5. Wiring connection
3. Charge voltage (Entire charging system)
NOTE:
??Remove the following parts before troubleshooting.
1) Seat 4) Fuel tank
2) Seat colwing 5) Lower cowling
3) Top cover
*Use the following special tools in this troubleshooting.
Inductive Tachometer: Pocket Tester:

P/N. Y U-08036 P/N. YU-03112
1. Fuse “MAIN” NO CONTINUITY

?? Connect the Pocket Tester (a x 1) to the
fuse “MAIN”.
?? Check the fuse “MAIN” for continuity. I Replace fuse “MAIN”.
CONTINUITY
a
Specific Gravity:
1.280 at 20°C (68” F)
CORRECT
a
*
8-35

* CHARGING SYSTEM
3. Charge voltage
n
?? Connect the Inductive Tachometer to spark
plug lead.
@Connect the Pocket Tester (DC20V) to the
battery
Tester (+) Lead -+ Battery (+I Terminal

Tester (-) Lead + Battery (-1 Terminal
- If
~Start the engine and accelerate to about,

3,000 r/min. MEETS SPECIFICATION
v
?? Check charging voltage.
rll
m Charging Voltage:
;8: 14.3 - 15.3V at 3,000 r/min
I
1 Replace battery.
I
1
I
J
1 OUT OF
SPECIFICATION
4. Stator coil resistance

?? Disconnect the A.C. magneto coupler from
the wire harness.
*Connect the Pocket Tester (R x 1) to the
stator coil leads.
Stator Coil (1)

Tester (+) Lead + White Lead @
Tester (-1 Lead + White Lead @
Stator Coil (2)

Tester (+) Lead + White Lead @
Tester (-) Lead + White Lead @
8-36

CHARGING SYSTEM pq-iq
6
2
W
w w
3
?? Check the stator coil for specificated resis-

tance.
Stator Coil Resistance:
White @ -White @
0.44 - 0.66R at 20°C (68” F)
White @ -White @
0.44 - 0.66R at 20°C (68” F) Replace stator coil.
I/‘
1 POOR q:;;ZTlON
Check the entire charging system for con-
Refer to the “WIRING DIAGRAM” section.

I
n
CORRECT
Replace rectifier/regulator.
I
8-37

LIGHTING SYSTEM ELECl m 1
LIGHTING SYSTEM
CIRCUIT DIAGRAM
I- r--7
I.4
-_r”
@ W/B
-
Ed
I
L/R
0
I 1
T
L, Br
Ch Dg
P -@ t -
8-39

LIGHTING SYSTEM
Aforementioned circuit diagram shows the lighting circuit in the wiring diagram.
NOTE:
@ Main switch
@ “START” switch
@ Fuse “MAIN”
@ Battery
@ Front position light (Left)
@ Front position light (Right)
@ Fuse “HEAD”
@$ “LIGHTS” (Dimmer) switch
@ Meter light
@ “HIGH BEAM” indicator light
@ Headlight
@Tail light
@License light
B-40

LIGHTING SYSTEM pqq
TROUBLESHOOTING
I HEADLIGHT, “HIGH BEAM” INDICATOR LIGHT, TAILLIGHT, LICENSE LIGHT

METER LIGHT, AND POSITION LIGHT DO NOT COME ON. I
Procedure
Check;
1. Fuse “MAIN” 4. “LIGHTS” (Dimmer) switch
3. Main switch (Entire lighting system)
NOTE:
?? Remove the following parts before troubleshooting.
1) Seat 3) Seat cowling
2) Upper cowling
Pocket Tester:
P/N. YU-03112
1. Fuse “MAIN” NO CONTINUITY

??Remove the fuse “MAIN”.
?? Connect the Pocket Tester (R x 1) to the
fuse “MAIN”.
aCheck the fuse “MAIN” for continuity. Replace fuse “MAIN”.
l-l
& CONTINUITY
2. Battery I INCORRECT
?? Refill battery fluid.
Specific Gravity: ?? Clean battery terminals.
1.280 at 20” C (68” F) ?? Recharge or replace battery.
CORRECT
8-41

*
pqq
LIGHTING SYSTEM
3. Main switch
a
D Disconnect the main switch couplers from
the wire harness.
nuity between “Red 0 and Brown @ “,
and “Red @) and Blue @ “. Refer to the
‘CHECKING OF SWITCHES” section.
INCORRECT
I
Replace main switch. I
4. “LIGHTS” (Dimmer) switch

) Disconnect the handlebar switch (Left)
nuity between “Blue/Black @ and Yellow
0 ” and Blue/Black @ and Green @ “.
section.
INCORRECT
1-
Replace handlebar switch (Left). I
8-42

* LIGHTING SYSTEM l=l liilii 1
a
. Disconnect the “START” switch coupler
from wire harness.
0 Check the “START” switch component for
the continuity between “Red/Yellow @ and
Blue/Black @ “. Refer to the “CHECKING
OF SWITCHES” section.
INCORRECT
Refer to the “WI RING DIAGRAM” section.
Check condition of each circuit for lighting
Refer to the “LIGHTING SYSTEM CHECK”
8-43

r
LIGHTING SYSTEM -1
LIGHTING SYSTEM CHECK
1. Headlight and “HIGH BEAM” indicator light do not come on.
1. Fuse “HEAD” NO CONTINUITY

?? Remove the fuse “HEAD”.
?? Connect the Pocket Tester (n x 1) to the
fuse “HEAD”.
?? Check the fuse “HEAD” for continuity. Replace fuse “HEAD”.
CONTINUITY
2. Bulb and bulb socket NO CONTINUITY

?? Check the bulb and bulb socket for conti-
nuity.
Refer to the “CHECKING OF BULBS”
section. Replace bulb and/or bulb socket.
I
v
l-l
CONTINUITY
3. Voltage
?? Connect the Pocket Tester (DC20V) to the
“LIGHTS” (Dimmer) switch connector.
Tester (+I Lead + Blue/Black @ Terminal

Tester (-1 Lead + Black @ Terminal
MEETS SPECIFICATION
@Turn the main switch to “ON”.

bCheck for voltage (12V) on the “Blue/-
Yellow” at the “LIGHTS” (Dimmer) switch IThis circuit is good.
connector,
c
I
8-44

* LIGHTING SYSTEM JELECII
n
Check the entire lighting system for connec-
tions.
2. Meter light does not come on.
1. Fuse “HEAD”
NO CONTINUITY
??Remove the fuse “HEAD”.
?? Connect the Pocket Tester (.Q x 1) to the
fuse “HEAD”.
?? Check the fuse “HEAD” for continuity. Replace fuse “HEAD”.
CONTINUITY
a
2. Bulb and bulb socket NO CONTINUITY
nuity.
Refer to the “CHECKING OF BULBS”
section. Replace bulb and/or bulb socket.
I
r l
CONTINUITY
3. Voltage
bulb socket connector.
Tester (+) Lead + Black/White 0 Terminal

Tester (-) Lead --f Black @ Terminal
8-45

LIGHTING SYSTEM -1
??Turn the main switch to “ON”. OUT OF SPECIFICATION

?? Check for voltage (12V) on the “Black/
White” lead at the bulb socket connector.
Check the entire lighting system for
;;;I
connections.
Refer to the “WIRING DIAGRAM”
section.
3.‘License light does not come on.
Replace bulb and/or bulb socket.

I
CONTINUITY
I--2. Voltage
the Pocket Tester (DC20V) to the
Tester (+I Lead + Blue @ Lead

Tester (-1 Lead + Black @ Lead
L l
BW
2
c ClXl l
-CD+
a
I ??Turn the main switch to “ON”.
I ?? Check for voltage (12V) on the “Blue” lead

at the bulb socket connector.
a
Iirinq connection
MEETS
SPECIFICATION (12V)
I I connections.
This circuit is good. Refer to the “WIRING DIAGRAM”
section.
8-46

LIGHTING SYSTEM
4. Taillight does not come on.
NO CONTINUITY
@Check the bulb and bulb socket for conti-
\,
, ,

CONTINUITY
a
2. Voltage
~Connect the Pocket Tester (DC20V) to the
Tester (+) Lead + Blue @ Terminal

Tester (-) Lead -+ Black @ Terminal
D Turn the main switch to “ON”.

BTurn the “LIGHTS” switch to “ON”.
DCheck for voltage (12V) on the “Blue” lead
at the bulb socket connector.
n
MEETS
J 3. Wiring connection
connections.
Refer to the “WIRING DIAGRAM”
SPECIFICATION (12V)
section.
This circuit is good.
I
8-47

LIGHTING SYSTEM -1
4. Taillight does not come on.
NO CONTINUITY
*Check the bulb and bulb socket for conti-
Replace bulb and/or bulb socket. I

CONTINUITY
a
2. Voltage
) Connect the Pocket Tester (DC20V) to the
Tester (+) Lead --f Blue 6) Terminal

Tester (-) Lead + Black @ Terminal
) Turn the main switch to “ON”.

BTurn the “LIGHTS” switch to “ON”.
~Check for voltage (12V) on the “Blue” lead 3. Wiring connection
at the bulb socket connector. Check the entire lighting system for
i
n connections.
MEETS
SPECIFICATION (12V) Refer to the “WIRING DIAGRAM”
section.
8-47

SIGNAL SYSTEM 1 ELECl i=i 1
SIGNAL SYSTEM
CIRCUIT DIAGRAM
ObJRIBrlLl - \ N - AZ?
I!Lu
I I I Liwl RIW- L/R\ -1
L/W ’
0 1 L/W L/W 1 Y
I II IL 1I
I
I
LB r
III -- IN’- -..I
1byiiqB,
.-------a
I I
rch c "cmLl
8-49

SIGNAL SYSTEM lELEcl m 1
Aforementioned circuit diagram shows the signal circuit in the wiring diagram.
NOTE:
@Main switch @Cancelling unit (Relay assembly @ )

@ “START” switch @ “TURN” switch
@ Fuse “MAIN” @ “TURN” indicator light
@J Battery @ Front flasher light (Left)
(j-j Diode block @ Rear flasher light (Left)
@ Digital ignitor unit @I Rear flasher light (Right)
@I Fuse “SIGNAL” @I Front flasher light (Right)
@Front brake switch @ Reed switch
@ Rear brake switch @ Horn
@“NEUTRAL” indicator light @ “HORN” switch
@) Neutral switch @Tachometer
@ “01 L” indicator light @ Temp meter
@Th ermo unit
@R esistor
@Oil level switch @Brake light
@I Flasher relay (Relay assembly 0)
B-50

SIGNAL SYSTEM
TROUBLESHOOTING
?? FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT DO NOT COME ON.
. HORN DOES NOT SOUND.
?? TACHOMETER DOES NOT OPERATE.
Procedure
Check;
1. Fuse “MAIN” 4. Wiring connection
2. Battery (Entire signal system)
3. Main switch
NOTE:
1) Seat 3) Seat cowling
2) Lower cowling 4) Air filter case
Pocket Tester:
P/N. YU-03112
1. Fuse “MAIN” NON CONTINIJITY

?? Connect the Pocket Tester (fi x 1) to the
fuse “MAIN”.
aCheck the fuse “MAIN” for continuity. Replace fuse “MAIN”.
CONTINUITY
?L
1 2. Battery INCORRECT
I Specific Gravity:
1.280 at 20” C (68” F) I
?? Ciean battery terminals.
?? Recharge or replace battery.
a *
CORRECT
8-51

SIGNAL SYSTEM pEpiiq
3. Main switch
@Disconnect the main switch coupler from
the wire harness.
nuity between “Red @ a n d B r o w n @ “.
section.
INCORRECT
I Replace main switch.

I” -
I
I
CORRECT
) 4n/iring c o n n e c t i o n
POOR CONNECTION
Check the entire signal system for connec-
Refer to the “WI RING DIAGRAM” section. 4

a CORRECT
Check condition of each circuit for signal

IC orrect. I
system.
Refer to the “SIGNAL SYSTEM CHECK”
section.
8-52

SIGNAL SYSTEM -1
SIGNAL SYSTEM CHECK
1. Horn does not sound.
1. “HORN” switch
?? Disconnect the handlebar switch coupler
nuity between “Pink @ a n d B l a c k @ “.
section.
\P B
OFF (Free)
ON (Push) ckn
INCORRECT
‘11
CORRECT
I Replace handlebar switch (Left). I
2. Voltace
horn connector.
Tester (+) Lead + Brown @ Lead

Tester (-) Lead + Frame Ground
II
#Turn the main switch to “ON”.
@Check for voltage (12V) on the “Brown” Check the entire lighting system for
lead at the horn terminal. connections. I
l-l MEETS
SPECIFICATION (12V)
w
*
8-53

* SIGNAL SYSTEM
3. Horn
a
?? Disconnect the “Pink” lead at the horn
terminal.
?? Correct a jumper lead @I to the horn termi-
nal and ground the jumper lead.
?? Turn the mainswitch to “ON”.
+c HORN IS SOUNDED
t
1-
-
II
Horn is good.
HORN IS NOT
SOUNDED
4. Voltage
horn at the Pink terminal.
Tester (+) Lead -+ Pink @ Lead

Tester (-1 Lead -+ Frame Ground
?? Turn the main switch to “ON”.
?? Check for voltage (12V) on the “Pink” lead
at the horn terminal. +
I 1
a
1 Replace horn. I
MEETS SPECIFICATION
(12V)
1 Adjust or replace horn. I
8-54

SIGNAL SYSTEM
2. Brake light does not come on.
CONTINUITY
2. Brake switch
?? Disconnect the brake switch coupler from
the wire harness.
nuity between “Brown @ and Green/-
Yellow @ ” or “Brown @ and Yellow @ “.
section.
INCORRECT
a
??
Front brake switch
Rear brake switch r Replace brake switch. I
*Connect the Pocket Tester (DC20V) to the
I Tester (+) Lead + Blue @ Lead

Tester (-1 Lead + Black @ Lead I
8-55

SIGNAL SYSTEM -1
.-- - - OUT OF SPECIFICATION

~The brake lever is pulled in or brake pedal
is stepped down.
,Check for voltage (12V) on the “Yellow”
lead at the bulb socket connector.
4. Wiring connection 1
J Check the entire signal system for
_ _----
MttlS connections.
SPECIFICATION (12V) Refer to the “WIRING DlAGRAWl”
section.
3. Flasher light and/or “TURN” indicator light do not blink.
CONTINUITY
a
2. “TURN” switch
nuity between “Brown/White @ and
Chocolate @ ” and “Brown/White @
and Dark green @ Refer to the “CHECK-
INCORRECT
Replace handlebar switch (Left).

CORRECT
8
*
8-56

SIGNAL SYSTEM IELEC~ Ic3 1
??Turn the main switch to “ON”.
?? lhe brake lever is pulled in or brake pedal
,,Yellow,,
is stewed down. 1 4
?? Check for voltage (12V) on the 4. Wiring connection
lead at the bulb socket connector. Check the entire signal system for
MEETS connections.
SPECIFICATION (12V Refer to the “WIRING DIAGRAM”
a
This circuit is good. 1 section.
3. Flasher light and/or “TURN” indicator light do not blink.
CONTINUITY
a
2. “TURN” switch
) Disconnect the handlebar switch coupler
nuity between “Brown/White 0 and
Chocolate @ ” and “Brown/White @
and Dark green @ . Refer to the “CHECK-
INCORRECT
1 Replace handlebar switch (Left). I

CORRECT
8-56

SIGNAL SYSTEM (ELECII
3. Voltage
IConnect the pocket tester (DC2OV) to the
relay assembly connector.
Tester (+) Lead + Brown @ Terminal

Tester (--) Lead + Black @ Terminal
ilDCZOV
-I Q +
.I--’ OUT OF SPECIFICATION
‘Turn the main switch to “ON”.

~Check for voltage (12V) on the “Brown” Check the entire signal system for
lead at the flasher relay terminal.
n MEETS
-0 SPECIFICATION (12V)
4. Voltage
DConnect the pocket tester (DC20V) to the
relay assembly connector.
Tester (+) Lead -+ Brown/White @Terminal

Tester (-) Lead -+ Black @ Terminal
DTurn the main switch to “ON”.

BCheck for voltage (12V) o n t h e “ B r o w n / t 4 1
White” lead at the flasher relay terminal. 1Replace relay assembly. I
MEETS
SPECIFICATION (12V)
a
*
8-57

SIGNAL SYSTEM -1
5. Voltage
At Flasher Light (Left):

Tester (+) Lead + Chocolate (!I Lead
Tester (--) Lead -+ Frame Ground
At Flasher Light (Right):

Tester (+) Lead --f Dark yreen @ Lead
Tester (-) Lead + Frame Ground
DTurn the main switch to “ON”.
BTurn the “TURN” switch to “L” or “RI’.
1
D Check for voltage (12V) on the “Chocolate”
lead or “‘Dark green” lead at the bulb socket /_,:_
connector. Check the entire srgnal system for
_ I----
11 MttlS
+
SPECIFICATION (12V)
I Refer to the “WIRING DIAGRAM”
This circuit is good. I sectron.
4. Blinking (Flasher light) is not cancelled automatically.
1 1. “TURN” switch I
nuity between “Yellow/Red @ a n d B l a c k
@ ‘I.
section.
8-58

SIGNAL SYSTEM (ELEC(CY/
INCORRECT
Replace handlebar switch (Left).
CORRECT
2. Reed switch
?? Disconnect reed switch coupler from the
wire harness.
?? Connect the pocket tester (R x 1) to the
reed switch terminal.
Tester (+) Lead -+ White/Green @ Terminal

Tester (-) Lead -+ Ground
NOTE:
When measuring reed switch resistance,
lift front wheel and rotate the wheel by
hand.
?? Check the reed switch for specificated resis-

tance.
El Reed Switch Resistance:

c:@; l About 752
(White/Green - Ground)
Then return back OC2 or ~52
when wheel is stopped.
MEETS SPECIFICATION
I Replace speedometer assembly. I
POOR CONNECTION
Refertothe”WIRING DIAGRAM”section.
8-59

* SIGNAL SYSTEM pqji-
Replace relay assembly.

a
4. “NEUTRAL” indicator light does not come on.
1 1. Bulb and bulb socket I

@Check the bulb and bulb socket for conti- NO CONTINUITY
nuity. Refer to the “CHECKING OF
BULBS” section.
2. Neutral switch
a- CONTINUITY
I

the wire harness.
nuity between “Sky blue @ and Ground”.
section.
INCORRECT
I Replace neutral switch.
v-
~7
CORRECT
I 3. Voltage
??Connect the pocket tester (DC20V) to the

8-60

SIGNAL SYSTEM pqEii
Br
Sb
B Turn the main switch to “ON”.

B Check for voltage (12V) on the “Brown”
1 6. Wirinq connection I
r
lead at bulb socket connector.
- ..---- Check the entire signal system for
MEETS I
SPECIFICATION (12V)
5. “01 L” indicator light does not come on when push “START” switch.
NO CONTINUITY
1. Bulb and bulb socket
nuity. Refer to the “CHECKING OF
BULBS” section. Replace bulb and/or bulb socket.
1
CONTINUITY
a
?? Disconnect the “START” switch coupler
from wire harness.
?? Check the “STAR” switch component for
the continuity between “Blue/White @
and Black @ “. Refer to the “CHECKING
OF SWITCHES” section.
INCORRECT
Replace handlebar switch (Right). I
a CORRECT
8-61

SIGNAL SYSTEM -1
3. Diode
B Disconnect the diode unit coupler from the
wire harness.
r Connect the pocket tester K2 x 1) to the
diode leads.
Tester (+) Lead -+ Blue/White @Lead

Tester (-1 Lead + Green @ Lead
NO CONTINUITY
?? Check the diode for continuity.
4. Voltage
n CONTINUITY
?? Connect the pocket tester (DC20V) to the

Tester (t) Lead -+ Brown @Terminal

Tester (-) Lead + Black @Terminal
8-62

SIGNAL SYSTEM -1
]lli
?? Check for voltage (12V) on the Brown
1 1
MEETS 5. Wiring connection
SPECIFICATION (12V) Check the entire signal system for
a
6. “01 L” indicator light does not come on, when oil tank is empty.
aCheck the bulb and bulb socket for conti-

-
CONTINUITY
2. Resister
aDisconnect the diode unit coupler from the
wire harness.
*Connect the pocket tester (R x 1) to the
diode leads.
Tester (+) Lead += Black/Red @ Lead

Tester (-1 Lead + Green @ Lead
NO CONTINUITY
@Check the resister for continuity. 1 Replace diode unit. I

-
QCONTINUITY
8-63

SIGNAL SYSTEM piqq
3. Oil level switch

?? Remove the oil level switch from the oil
tank.
@Connect the pocket tester (L! x 1) to the oil
level gauge.
Tester (+I Lead -+ Black/Red @Terminal

Tester (-1 Lead + Oil Level Switch Body
*Check the oil level switch for continuity.
Switch Good
Bad condition
position condition
A Upright
X 0 x 0
position BAD CONDITION
Upside
B down 0 x x 0
position
3: Continuity x : No continuity eplace oil level switch.
GOOD CONDITION
a
4. Voltage
@Connect the Pocket Te-ter (DC20V) to the

Tester (-) Lead + Black @Terminal
8-64

SIGNAL SYSTEM ppiq
*Turn the main switch to “ON”.
@Check for voltage (12V) on the “Brown”
lead at bulb socket connector.
l-l MEETS
SPECIFICATION (12V) Check the entire signal system for
*
connections.
This circuit is good. Refer to the “WIRING DIAGRAM”
I
section.
7. When engine is hot, tempmeter does not move.
1. Tempmeter
?? Disconnect the therm0 unit lead (Green/-
Red) @ .
?? Check that the tempmeter stays put at “C”.
?? Ground the lead to the frame with the
jumper lead.
?? Turn the main switch to “ON”.
ACAUTlUN;
?? Check that the tempmeter hand moves up As soon as the meter hand get in the
to “H”. “Red zone, turn the main switch to
“OFF” to avoid damage to the temp-
meter.
CORRECT
II v
Check wiring connection.
1
I
I INCORRECT
8-65

.
SIGNAL SYSTEM -1
2. Therm0 unit
?? Remove the therm0 unit.
?? immerse the therm0 unit @ in coolant 0.
?? Measure the resistance at each temperature
as tabulated.
@ Therm0 meter
Handle the therm0 unit with special care.
Coolant Never subject it to strong or allow it to
Resistance
Temoerature I be dropped. Should it be dropped, it
50°C (122” F) 154s2 must be replaced.
80°C (178” F) 47 - 57fl
100°C (212” F) 26 - 29~2
120°C (248” F)
ACAUTION:
Avoid overtightening.
wafter measuring the therm0 unit, install the

unit.
8-66

SIGNAL SYSTEM -1
MEETS
SPECIFICATIONS I Replace therm0 unit. I
5. Voltage
‘Connect the pocket tester (DC20V) to the
temperature gauge leads.

Tester (-1 Lead -+ Black @ Terminal

ICheck for voltage (12V) on the “Brown”
lead ,at the temperature gauge connector.
n MEETS
lolnnprlionl]
Check the entire signal system for
e SPECIFICATION (12V)
POOR CONNECTION
~6. Wiring connection
Check the entire signal system for connec-
tions. Refer to the “WIRING DIAGRAM”
section. Correct.
a
I
CORRECT
Replace tempmeter. I
8-67

COOLING SYSTEM 1 ELECi ii@ 1
COOLING SYSTEM
CIRCUIT DIAGRAM
L Br
-LI /R - ! L(D I - G -
8-69

COOLING SYSTEM [ELECII
A forementioned circuit diagram shows the cooling circuit in the circuit diagram.
NOTE:
@Main switch
@Fuse “MAIN”
@B attery
@Fuse “FAN”
@Thermo switch
@Fan motor
8-70

COOLING SYSTEM
TROUBLESHOOTING
FAN MOTOR DOES NOT TURN.

I
Procedure
Check;
1. Fuse “MAIN/FAN” 5. Therm0 switch
3. Fan motor (Test 1) (Entire cooling system)
4. Fan motor (Test 2)
NOTE:
1) Seat 3) Air filter case

2) Top cover
Pocket Tester:
P/N. YU-03112
1. Fuse “MAIN/FAN” NO CONTINUITY

?? Remove the fuse “ M A I N ” and “FAN”.
@Connect the Pocket Tester (G x 1) to the
fuse “MAIN” and “FAN”.
?? Check the fuse for continuity. Replace fuse “MAIN” and/or “FAN”.
2. Battery
a CONTINUITY
INCORRECT
Specific Gravity:
1.280 at 20°C (68” F)
CORRECT
47
*
8-71

?? Disconnect the fan motor coupler.
?? Connect the battery voltage as shown.
Battery (+) Lead -+ Blue @ Terminal

Battery (-) Lead + Black @ Terminal
1,._
NO OPERATIVE
?? Check the fan motor for operation. Replace fan motor.

a OPERATIVE
?? Disconnect the therm0 switch coupler.

?? Connect the terminal with the jumper @
lead as shown.
NO OPERATIVE
I I Check wiring connection(s). I
l-l OPERATIVE
a-72

COOLING SYSTEM -1
-x-
a
5. Therm0 switch
?? Remove the therm0 s w i t c h f r o m t h e
thermostat housing.
*Connect the pocket tester (0 x 1) to the
therm0 switch @ .
?? Immerse the therm0 switch in the water
0.
?? Check the therm0 switch for continuity.
Note temperatures while heating the water
with the temperature gauge @ .
Test Good
Water Temperature
Step Condition Handle the therm0 switch with special care.
-
0- 98°C Never subject it to strong shock or allow it to be
1 X
(32 - 208.4” F) dropped. Should it be dropped, it must be
More than 105 + 3°C replaced.
2 0
(221.0 2 5.4”F)
I
105 to 98°C
3” 0 Therm0 Switch:
(221 .O to 208.4” F)
_- 8 Nm (0.8 m-kg, 5.8 ft.lb)
Less than 98°C Three Bond Sealock@ # 10 I
4” X
(208.4” F)
Test 1 & 2; Heat-up tests
A CAUTION:
Test 3” & 4”; Cool-down tests
After replacing the therm0 switch, check the
3 : Continuity X : No continuity
cooland level in the radiator and also check for
any leakage.
NOTE:
The electric fan is controlled by the therm0
switch whenever the main switch is “ON” or
“OFF”. Thus, under certain operating condi-
tions, this fan may continue to run until the
engine temperature has cooled down to about
98°C (208°F).
8-73

COOLING SYSTEM IELEC~ m 1
[El THERM0 SWITCH “ON”, FAN “ON”
[s) COOLANT TEMPERATURE
BAD CONDITION
98OC 105+3°c
(208.4’F) (221 .O + 5.4’F)
El 1 Reolace therm0 switch. I

GOOD CONDITION
?? Check the entire cooling system for connec-
Refer to the “WIRING DIAGRAM” section.
Fan Motor Inspection

The following problems may require repair or
replacement of components
Component Condition
Fan motor Unsmooth operation
Fan motor Excessive vibration
Fan motor bracket Cracks
Fan blades Cracks
Securing bolts Looseness
8-74

FUEL SYSTEM
FUEL SYSTEM
CIRCUIT DIAGRAM

FUEL SYSTEM 1 ELECl
A forementioned circuit diagram shows the fuel circuit in the circuit diagram.
@Main switch
@Fuse “MAIN”
@Battery
@Fuse “IGNITION”
@-ENGINE STOP- switch
@I Digital ignitor unit
@Fuel pump relay
@Fuel pump
8-76

FUEL PUMP CIRCUIT OPERATION @ To main fuse and battery
The fuel pump circuit consists of the fuel pump @ Main switch
relay, fuel pump, “ENGINE STOP” switch and
@ Digital ignitor unit
digital ignition unit.
@ Fuel pump relay
The digital ignition unit includes the control @ Fuel pump
unit for the fuel pump.
The fuel pump starts and stops as indicated in
the chart below.
FUEL PUMP
START STOP
@Main/Engine stop switch ?? Engine turned on ?? Engine turned off

turned to “ON”
For about 5 seconds when car- After about 0.1 second After about 5 seconds
buretor fuel level is low
a-77

FUEL SYSTEM p+iiiij
TROUBLESHOOTING
FUEL PUMP FAILS TO OPERATE.

I- I
Procedure
1 . Fuse “MAIN/IGNITION” 5 . Fuel pump relay
2 . Battery 6 . Fuel pump
3 . Main switch 7 . Wiring connection
4. “ENGINE STOP” switch (Entire fuel system)
NOTE:
1) Seat
2) Fuel tank
Pocket Tester:
YU-03112
1. Fuse “MAIN/IGNITION” NO CONTINUITY

?? Remove the fuse “MAIN” and “IGNITION”
?? Connect the Pocket Tester (n x 1) to the
fuse “MAIN” and “IGNITION”.
?? Check the fuse for continuity. Replace fuse “MAIN” and/or “IGNI-
, TION”
l-l CONTINUITY

Specific Gravity: ?? Clean battery terminals.
1.280 at 20°C (68” F) ?? Recharge or replace battery.
CORRECT
a
*
8-78

* FUEL SYSTEM 1 ELECT
3. Main switch
a
?? Disconnect the main switch coupler and lead
nuity between “Red @ and Brown @ “.
section.
INCORRECT
1 Replace main switch. I

CORRECT
a
nuity between “Red/White (ij and Red/-
SW ITCH ES” section.
INCORRECT

CORRECT
a
*
8-79

FUEL SYSTEM -1
5. Fuel oumo relav

?? Disconnect the fuel pump relay coupler
?? Connect the pocket tester (52 x 1) and
battery (12V) v o l t a g e t o t h e f u e l p u m p
relay coupler terminals.
Tester (+I Lead -+ Blue/Black @ Terminal

Tester (-1 Lead+ Red/White @ Terminal
Battery (+I Lead + Red/White @ Terminal
Battery (-) Lead+Blue/White @ Terminal
NO CONTINUITY
?? Check the relay for continuity. Replace fuel pump relay.
CONTINUITY
8
6. Fuel pump
?? Disconnect the fuel pump coupler from
the wire harness.
. Connect the battery voltage as shown.
Battery (+I Lead --f Blue/Black @Terminal

Battery (-1 Lead+ Black @ Terminal
NO OPERATIVE
BCheck the fuel pump operation. Replace fuel pump.
OPERATIVE
8-80

FUEL SYSTEM -1
1. 7. Wiring co;nection
1 POOR. CONNECTION
Check the entire fuel system for connectlons
CORRECT
Correct.
Replace digital ignitor unit.
8-81

FUEL SYSTEM
FUEL PUMP TEST
Operation
The diaphragm is pulled in by the plunger allow-
ing fuel to be sucked into the fuel chamber.
Fuel is pushed out from the pump until carb
float chamber is filled with fuel, and then the
cut-off switch cuts off the circuit.
When the spring pushes the diaphragm further
to the end, the cut-off switch turns on and the
solenoid coil pulls the plunger with the dia-
phragm forcing fuel into the fuel chamber.
NOTE:
When the main and “ENGINE STOP” switches
are ON, the fuel pump relay is activated for five
(5) seconds at which time the fuel pump
operates.
@ Cut-off switch
@ Spring
@ Diaphragm
@ Plunger
@ Solenoid coil
g E;;;;hamber
@ Outlet
@ Inlet
Inspection
1. Connect:
?? Battery ( 12V)
2. Inspect:
@Fuel pump
Cracks/Damage -+ Replace.
3. Check:
?? Fuel pump operation
Faulty operation -j. Replace.
8-82

YAMAHA EXHAUST VARIABLE VALVE SYSTEM (For California only)
CIRCUIT DIAGRAM
. I ---R/W-----4
! I I I I R/W-L-R/WA I I I
-
I
II
8-83

YAMAHA EXHAUST VARIABLE VALVE SYSTEM IELECl Iid [
A forementioned circuit diagram shows the cooling circuit in the circuit diagram.
NOTE:
@Main switch
@Fuse “MAIN”
@Battery
@ Fuse “IGNITION”
@“ENGINE STOP” switch
@Digital ignition unit
@$ EXUP control unit
@ EXUP servomotor
P
8
8-84

TROUBLESHOOTING
WHEN MAIN SWITCH IS TURNED TO “ON”, EXUP SERVOMOTOR DOES

NOT OPERATE ONE CYCLE.
Procedure (1) Procedure (2)

Check; Check;
1. Voltage 1. Fuse “MAIN/IGNITION”
2. EXUP servomotor operation 2. Battery
3. EXUP servomotor operation 3. Main switch
4. Wiring connection 4. “ENGINE STOP” switch
(Entire EXUP system) 5. Wiring connection
(Entire EXUP system)
NOTE:
1) Seat 3) Lower cowling (Left)
2) Seat cowling
Pocket Tester:
P/N. YU-03112
Procedure ( 1)
1. Voltage
@Connect the pocket tester (DC20V) to the
“EXUP control unit ” @ connector.
Tester (+) Lead -+ Red/White @ Terminal

8-85

YAMAHA EXHAUST VARIABLE VALVE SYSTEM -1
@Turn the main switch to “ON” and check

for the voltage between “Black and Red/- OUT OF SPECIFICATION
White”.
Voltage (Red/White - Black):

4
lo- 14v I Go to the “Procedure (2)“. I
n MEETS
SPECIFICATION
+
2. EXUP servomotor operation OPERATIVE
?? Disconnect the EXUP cables from the pulley.
?? Turn the main switch to “ON” and check
the EXUP servomotor operation.
1 Seized or damaged power valve at 1
a
3. EXUP servomotor operation
NO OPERATIVE I muffler.
??Disconnect the EXUP servomotor @ coupler.

?? Connect the battery leads to the EXUP
servomotor terminal.
Battery Positive Lead + Black/Red @ Lead

Battery Negative Lead + Black/Yellow @
Lead
NO OPERATIVE
This test should be performed within a few

seconds to prevent further damage. I Replace EXUP servomotor. I
OPERATIVE
a
3t
8-86

YAMAHA EXHAUST VARIABLE VALVE SYSTEM wELEC(
Check the entire EXUP system for connec-

1 Reolace EXUP control unit. I
Procedure (2)
1. Fuse “MAIN/IGNITION”
NOCONTINUITY
?? Remove the fuse “MAIN” and “IGNITION”.
*Connect the Pocket Tester (5.? x 1) to the
fuse “MAIN” and “IGNITION”.
?? Check the fuse for continuity. Replace fuse “MAIN” and/or “IGNI-
TION”.
CONTINUITY
?J
?? Check the battery condition.
*Refer to the “BATTERY INSPECTION”
Specific Gravity:
1.280 at 20” C (68” F)
CORRECT
3. Main switch
?? Disconnect the main switch coupler and lead
from the wireharness.
?? Check the switch component for the con-
tinuity between “Red @ and Brown @ “.
section.
8-87

YAMAHA EXHAUST VARIABLE VALVE SYSTEM -1
INCORRECT
1 Replace main switch. I

CORRECT
8
ICheck the switch component for the con-
tinuity between “Red/White @ and Red/
R/W R/W
OFF
INCORRECT
c
I
Replace handlebar switch (Right). I
Go to “Procedure (1)”
8-88

METER ASSEMBLY -1
METER ASSEMBLY
@Speedometer @Meter bracket
@Tachometer 0 Bulb
@ Tempmeter @ Bulb socket leads
@ Indicator lights unit @ Speedometer cable
@Damper
16 Nm (0.6 m-kg, 4.3 ft.lb))
8-89

METER ASSEMBLY
REMOVAL
1. Remove:
?? Upper cowling

in the CHAPTER 3.
2. Disconnect:
?? Bulb socket coupler @
?? Speedometer cable @
3. Remove:
?? Speedometer assembly @
4. Remove:
?? Damper @
5. Remove:
0 Indicator light unit @
?? Meter bracket @
6. Remove:
?? Bulb socket lead
8-90

METER ASSEMBLY -1
INSTALLATION
‘3 “, ‘W/G” Reverse the “REMOVAL” procedure.
1. Install the meter lights and leads as shown.
--“B”“BN’.‘”
2. Install the indicator lights as shown.
8-91

TROUBLESHOOTING
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING 1
FUEL STEM PROBABLE CAUSE
Fuel tank ?? Empty
? Clogged fuel filter
? Clogged fuel breather pipe
-7 ? Deteriorated fuel or fuel containing water

or foreign material
*Fuel cock ?? Clogged fuel hose
.o Deteriorated fuel, fuel containing water or

foreign material
?? Clogged pilot jet
?? Clogged pilot air passage
?? Sucked-in air
?? Deformed float
?? Groove-worn needle valve
?? Improperly sealed valve seat
?? Improperly adjusted fuel level
0 Improperly set pilot jet
?? Clogged starter jet
0 Starter plunger malfunction
-o Improperly adjusted starter cable
-Air filter element ?? Clogged
-Fuel Pump-L: ~;~~~: ::I; ;;lg relay
9-1

pip-1
STARTING FAILURE/HARD STARTING SHTG
ELECT CAL SYSTEM

Spark plug 0 Improper plug cap
?? Worn electrodes
?? Wire between terminals broken
?? Improper heat range
?? Faulty spark plug cap
?? Broken or shorted primary/secondary
-ignition coil’-f:f%;;yns;Iky plug lead
-Full-transistor system ?? Faulty igniter unit
?? Faulty pickup coil
-Switches and wiring -o Faulty main switch
?? Faulty engine stop switch
?? Broken or shorted wiring
?? Faulty neutral switch
?? Faulty starter motor switch
?? Faulty sidestand switch
-o Faulty clutch switch
-Starter motor ? Faulty starter motor
? Faulty starter relay
? Faulty circuit cut-off relay
--I? Faulty starter clutch
COMPRESSION SYSTEM
Cylinder and cylinder head ? Loose spark plug
? Loose cylinder head or cylinder
? Broken cylinder head gasket
?? Worn, damaged or seized cylinder
9-2

pip-j
POOR IDLE SPEED PERFORMANCE SHTG
-Piston and piston rings ? improperly installed piston ring
? Worn, fatigued or broken piston ring
? Seized piston ring
-I ? Seized or damaged piston
-Crankcase and crankshaft ?? Improperly seated crankcase
?? Damaged crankshaft oil seal lip
?? Improperly sealed valve
?? Improperly contacted valve and valve seat
0 Improper valve timing
?? Broken valve spring
?? Seized crankshaft
-0 Seized camshaft
POOR IDLE SPEED PERFORMANCE
POOR LE SPEED PERFORMANCE PROBABLE CAUSE
Carburetor =o Improperly returned starter plunger
0 Loose pilot jet
?? Clogged pilot air jet
?? Improperly synchronized carburetors
?? Improperly adjusted idle speed

(Throttle stop screw)
?? Improper throttle cable play
-o Flooded carburetor
-Electrical system -0 Faulty battery
?? Faulty spark plug
?? Faulty igniter unit
?? Faulty pickup coil
-o Faulty ignition coil
-Valve train ?? Improperly adjusted valve clearance
9-3

POOR MEDIUM AND HIGH SPEED PERFORMANCE/
FAULTY GEAR SHIFTING
1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 1
POOR MEDIUM AND HIGH SPEED PERFORMANCE

Refer to “Starting failure/Hard starting.” (Fuel system, electrical system,
system and valve train)
PROBABLE CAUSE
? Improper jet needle clip position
? Diaphragm malfunction
? Improperly adjusted fuel level
?? Clogged or loose main jet
?? Clogged air filter
?? Faulty fuel pump
1 FAULTY GEAR SHIFTING 1
HARD SHIFTING
Refer to “Clutch dragging.”
SHIFT PEDAL DOES NOT MOVE PROBABLE CAUSE

?? Improperly adjusted shift rod
Shift shaft 7. Bent shift shaft
Shift cam, shift fork ? Groove jammed with impurities
? Seized shift fork
7 ? Bent shift fork guide bar
iT r a n s m i s s i o n - - L : ~~;~e;;;p~r~io; gear
?? Incorrectly assembled transmission
JUMP-OUT GEAR
Shift shaft-L* Improperly adjusted
?? Improperly returned stopper lever
Shift fork ?? Worn shift fork
Shift cam-[: ;opw)“,4:::y;;yrok’e
r Transmission ?? Worn gear dog

9-4

ITRBL/?l
CLUTCH SLIPPING/DRAGGING SHTG
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING PROBABLE CAUSE
“utch~-l: :::;:::;u:::‘l;:ing
?? Worn friction plate/clutch plate
t Engine oil70 Low oil level
L. Improper quality/viscosity
CLUTC DRAGGING
.Clutch -0 Warped pressure plate
?? Unevenly tensioned clutch springs
?? Match marks not aligned
?? Bent push rod
?? Loose push rod/bent clutch boss nut
?? Burnt primary driven gear bushing
?? Bent clutch plate
0 Swollen friction plate
?? Faulty cylinder kit cup
- ?? Broken clutch cable
- E n g i n e oil-,: ,:Cr;;IF
0 I m p r o p e r qualrty/viscosity
9-5

???? ?
OVERHEATING OR OVER-COOLING SHTG ?
OVERHEATING OR OVER-COOLING 1
OVERHEATING
-Ignition system ? Improper spark plug gap
? Improper spark plug heat range
7 ? Faulty ignitor unit
?? Improper carburetor main jet (setting)
?? Improperly adjusted fuel level
-Fuel systemi. Clogged air cleaner element
-Compression system ?? Heavy carbon build-up
-Engine Oil-L; ~~~~~~~;ty
-Brake ?? Dragging brake
-Cooling system ?? Faulty water temperature meter
?? Faulty thermo-unit
0 Incorrect cooling water level
?? Faulty thermostat
?? Clogged or damaged radiator
?? Faulty radiator cap
?? Broken dowel pin/tipped gear
?? Faulty thermoswitch
-0 Inoperative fan motor
OVER-COOLING
L Cooling system ? Faulty water temperature meter
? Faulty thermo-unit
? Faulty thermostat
? Faulty thermoswitch
? Inoperative fan motor
9-6

FAULTY BRAKE/
FRONT FORK OIL LEAKAGE/MALFUNCTION
FAULTY BRAKE
POOR BRAKING EFFECT ?? Worn brake pads
?? Worn disc
?? Air in brake fluid
?? Leaking brake fluid
?? Faulty cylinder kit cup
?? Faulty caliper kit seal
?? Loose union bolt
?? Broken brake hose
?? Oily or greasy disc/brake pads
.o Improper brake fluid level
FRONT FORK OIL LEAKAGE/MALFUNCTION
OIL LEAKAGE Bent, damaged or rusty inner tube
Damaged or cracked outer tube
Damaged oil seal lip
Improperly installed oil seal
Improper oil level (too much)
Loose hexagon bolt (front fork bottom)
Broken cap bolt O-ring
Loose drain bolt
Damaged drain bolt gasket
MALFUNCTION ?? Bent, deformed or damaged inner tube
?? Bent or deformed outer tube
?? Damaged fork spring
?? Worn or damaged slide metal
?? Bent or damaged piston
-0 Improper oil viscosity or level
9-7

ITRBLJ?)
INSTABLE HANDLING SHTG
INSTABLE HANDLING
HANDLEBARS ?? Improperly installed or bent
?? Improperly installed handle crown
sTEER’NG1l: ~~~S’b”,“,d:“,”
?? Uneven oil levels on both sides
FRoNT FoRKs-ll ~~i~~~~~~~~forks
I
0 Unevenly worn tires
0 Incorrect tire pressure
? Uneven tire pressures on both sides
? Loose bearing
? Bent or loose wheel axle
? Excessive wheel run-out
FRAME :[T w i s t e d
?? Damaged head pipe bearing race
?? Improperly installed bearing race
REAR ARM ~1 vV;;a;Iyng bushes
DRIVE CHAIN ?? Improperly adjusted chain
9-8

FAULTY SIGNALS AND LIGHTS
FAULTY SIGNALS AND LIGHTS
HEADLIGHT DARK ?? Improper bulb
?? Too many electrical accessories
?? Hard charging (broken stator coil wire,

faulty rectifier with regulator)
? Incorrectly connected coupler/connector/

wire harness
? Improperly grounded
? Poor contacts (main or light switch)
? Bulb life expired
BULB BURNT OUT ?? Improper bulb
?? Faulty battery
?? Faulty rectifier/regulator
?? Improperly grounded
?? Faulty switch (main and light switch)
?? Bulb life expired
FLASHER DOES NOT LIGHT ? Improperly grounded
I
? Discharged battery
? Faulty flasher switch
? Faulty flasher relay
a Broken wire harness/loosely connected coupler
? Bulb burnt out
FLASHER KEEPS ON s-r Faulty yasher relay
?? lnsuffrcrent battery capacity (nearly discharged)
?? Bulb burnt out (front or rear)
9-9

1’““‘1?]
FAULTY SIGNALS AND LIGHTS SHTG
FLASHER WINKS SLOWER ? Faulty flasher relay
? Insufficient battery capacity (nearly discharged)
? Improper bulb
-I ? Faulty switch (main or flasher switch)
FLASHER WINKS QUICKER ?? Improper bulb
?? Faulty flasher relay
HORN IS INOPERATIVE ? Faulty battery
? Faulty switch (main or horn switch)
? Improperly adjusted horn
? Faulty horn (coil wire broken or having

poor contacts)
? Broken wire harness
FAULTY EXUP (For California only)

FAULTY EXUP
?? Seized or damaged power valve
‘Ower valve 7. Carbon build-up
Control c a b l e - c o Improperly adjusted cable

?? Seized or discontinuous cable
E Electrical parts ?? Insufficient battery capacity

(Improperly charged battery)
?? Faulty main switch
?? Faulty EXUP servo motor
?? Faulty ignitor unit
?? Faulty EXUP control unit

7 ?? Broken or shorted wiring
Q-IO

J I II

FOX Racing Shox
Setup Manual
MOTORCYCLE

Introduction
Thank you for choosing FOX Racing Shox for your motorcycle. In doing so, you have chosen the
number one shock absorber in the industry! All FOX Racing Shox products are designed, manufactured
and assembled by the finest professionals in the industry. You need to be aware of the importance of
setting up your new shock correctly to ensure maximum performance. This manual will provide you
with step-by-step instructions on how to set up your shock.
Table of Contents
FOX RACING SHOX History ....................................................................................................................3
General Information.....................................................................................................................................3
Warranty ......................................................................................................................................................3
Valving Warranty.........................................................................................................................................4
Optional Springs ..........................................................................................................................................4
Service..........................................................................................................................................................4
Methods of Payment ................................................................................................................................4
Replacement Parts........................................................................................................................................4
Methods of Shipping....................................................................................................................................4
Return Policy ...............................................................................................................................................4
International Orders .....................................................................................................................................5
Disclaimer ....................................................................................................................................................5
Installation and Basic Set-Up Instructions...................................................................................................5
Shock Length Adjustment / Ride Height Adjustment (If equipped) ......................................................5
Setting SAG / Spring Preload ..................................................................................................................5
Damping Adjustment (if equipped) .........................................................................................................7
Tuning Instructions ......................................................................................................................................7
Spring Preload..........................................................................................................................................7
Ride Height / Shock Length Adjustment (if equipped) ...........................................................................7
When to adjust Ride Height vs. Spring Preload ..................................................................................8
Damping...................................................................................................................................................9
Summary of Damping Solutions............................................................................................................10
Maintenance Checklist...............................................................................................................................11
Other Maintenance Considerations........................................................................................................11

FOX RACING SHOX History
Back in the mid-70’s Bob Fox, an avid motocross racer, came to the conclusion that the quality and
performance of the shock absorbers available for motocross racing were not up to the extreme demands
of the sport. As a mechanical engineer, he saw an opportunity to design and develop a new shock that
would surpass the performance of current race equipment. With that goal in mind, Bob designed and
began manufacturing a revolutionary high-performance, externally adjustable, air-pressurized shock
absorber. FOX AirShox were born!
When Bob first designed shocks for motocross competition, he envisioned a product that would be the
very Best available. Today, that same philosophy continues to drive FOX RACING SHOX.
We continue to push the envelope in racing shock absorber design, technology and performance shocks
for Motorcycles, Snowmobiles, Mountain Bikes, Off-Road vehicles, and ATV’s. And we continue to
develop our products based on our years of unique experience. Experience that has covered a wide
variety of the most extreme, most demanding shock absorber applications on the planet.
The countless lessons we’ve learned from the many forms of racing and the numerous top racers we’ve
worked with...the expertise we’ve gained in 25 years of experience...the tiny details of shock design and
manufacture that we know are so important...the unique shock designs and technology we’ve
developed...
All of this has been brought together to create one single product...
...A FOX RACING SHOCK for YOU!
General Information
FOX Racing Shox Phone: 831.768.1100
130 Hangar Way FAX: 831.768.1186
Watsonville, CA 95076 E-Mail: sales@foxracingshox.com
Business Hours: Monday-Friday 8:00 AM to 5:00 PM (Pacific Time Zone)
Warranty
The factory warranty period for your shock is one year from original date of purchase of the shock. A
copy of the original purchase receipt must accompany any shock being considered for warranty service.
This warranty is void when damage to the shock has occurred from the following:
• Abuse
• Damage to the exterior finish caused by improper hose routing.
• Disassembly
• Modifications
• Non-Factory authorized oil changes
• Shipping damages/loss (purchase of full value insurance is recommended).
FOX Racing Shox reserves the right to all final warranty decisions.
Warranty shipping is customer pre-paid one way. FOX Racing Shox will cover return ground shipping
only.

Valving Warranty
FOX Racing Shox guarantees satisfaction with your shock’s internal valving. If you are dissatisfied
with the internal valving of your shock, FOX Racing Shox will modify the valving at no charge within
one year of the purchase of the shock.
Optional Springs
FOX Racing Shox wants you to be able to extract the maximum amount of performance from your FOX
shock, therefore, we will recommend one of the spring rates available to ensure that the performance of
the shock is matched to your rider weight and riding style. If in the future you would like to change the
spring rate on your shock we can sell you additional springs through our aftermarket program. We
regret that once a shock has been shipped we are unable to exchange springs, so it is important that you
consider any special requirements at the time of purchase.
Service
Each and every FOX shock is carefully manufactured in our Watsonville, California facility. To ensure
peak performance, repairs and service to the shock must be performed by FOX Racing Shox or by an
authorized FOX Service center. Call (831) 768-1100 to find the service center nearest you. We
recommend that you have your shock serviced every two years for shocks used in normal conditions.
Follow this procedure to obtain service or repairs for your shock through FOX Racing Shox.
• Contact FOX Racing Shox for return authorization number and shipping address: (831) 768-1100.
• Send shocks to FOX Racing Shox with shipping charges pre-paid by sender.
• Mark the Return Address and Return Authorization Number clearly on the outside of the package.
• Include a description of the problem(s) with the shock, motorcycle information (manufacturer, year
and model) and return address with daytime phone number on a note.
Methods of Payment
VISA, MasterCard, Cashiers Check, COD Cash, Wire Transfers (International Orders)
Replacement Parts
Individual parts, different spring rates, and rebuild kits are available on all current shocks.
Methods of Shipping
All FOX shocks are stocked without springs mounted; we require 48 hours to properly assemble the
spring and ship your order. We offer UPS services of Ground, 2-Day, 3-Day or Overnight.
Return Policy
FOX Racing Shox will accept returns on new shock absorbers within 30 days of purchase from FOX
Racing Shox. All merchandise must be in the original box and cannot have been mounted on a
motorcycle. All returns are subject to a 20% restocking fee.

International Orders
All international orders must be paid in full prior to shipment. We suggest wire transfer, VISA or
MasterCard for pre-payments. Freight, any applicable duties or taxes must be pre-paid unless prior
arrangements have been made. Our most frequent method of shipping is UPS, but we will ship DHL or
another approved international shipper.
Disclaimer
A shock absorber is a key safety component of a motorcycle. FOX Racing Shox recommends that a
qualified mechanic install your shock absorber.
Motorcycling is an inherently dangerous activity. Always ride within the limits of your skill and your
equipment.
If these setup instructions are not followed correctly, an unsafe condition may exist. If you are
uncomfortable or uncertain as to how to install your new FOX shock, have it installed by a qualified
mechanic.
Installation and Basic Set-Up Instructions

Follow this sequence of steps to properly install and set up your new FOX shock.
1) Remove the stock shock absorber from the motorcycle.
2) Set the FOX shock length (if equipped with length adjustment). See section below.
3) Install the FOX shock on the motorcycle. Torque the mounting fasteners to the motorcycle
manufacturer’s recommendations.
4) Set the static sag and rider sag. See section below.
5) Set the rebound damping. See section below.
6) Set the compression damping (if equipped). See section below.
Shock Length Adjustment / Ride Height Adjustment (If equipped)

On some FOX shocks, it is possible to adjust the rear ride height of your bike, by increasing or
decreasing the length of your shock. It is best to start out with your FOX shock set to the same length
as the stock shock absorber. Once you have adjusted your spring preload and damping to your liking,
you can experiment with different rear ride height settings. See Tuning Instructions for more
information on adjusting rear ride height.
Setting SAG / Spring Preload

After fitting your FOX shock you need to set the static sag and rider sag. You will need a bike stand
that will let your suspension “hang” down in an unloaded position. The rear stand should mount onto
the foot pegs or the frame somewhere (not the swingarm), so that the rear wheel is off the ground. If
your motorcycle is equipped with a centerstand, that will suffice. If you do not have this type of stand, a
couple of strong friends should be sufficient.
1) Set the bike up on a suitable stand or get your friends to lift up the rear so the shock is fully
extended. Take a measurement from the rear axle to a point on the chassis directly above the rear
axle (see Figure 1). This is L1; write down this measurement.

2) Have a friend hold the front end of the
bike. Sit on the bike in your normal riding
position. It is also a good idea to have your
normal riding gear on including your
helmet. If you normally carry luggage on
your motorcycle, leave it on the motorcycle
for this measurement. Push down on the
rear of the bike then let it settle. Measure
the distance using the same points as
above. This is L2; write down this
measurement.
3) Rider sag = L1 – L2. On a street bike this
should be 25% to 35% of the total wheel
travel, or typically 1” – 1.5” (25-35 mm).
On a road race bike this should be ¾” - 1”
(20-25mm). (Your motorcycle owner’s
manual will tell you the total wheel travel.)
4) To set rider sag to the correct amount, use
the “C” wrench provided and adjust the
preload adjuster nuts on top of the spring.
Tighten the nut onto the spring to decrease
Figure 1: Measuring from the rear axle to a point
rider sag; loosen the nut to increase rider
on the chassis directly above the rear axle
sag. Repeat steps 2 through 4 until the
rider sag is in the desired range.
5) Push down on the rear of your motorcycle a couple of times and let it settle with no rider on board.
Measure using the same points as before. We will call this L3; write down this measurement.
6) Static sag = L1 – L3. The static sag should be between 0.25 - 0.5 inches (7-13 mm).
The following chart will enable you to determine if your spring rate is correct. The measurements given
are a guide only; there are no absolute settings that you must stick to.
Rider Sag Static Sag Spring Rate May Be:
Appropriate Range Too Little Too Soft
Appropriate Range Too Much Too Hard

Damping Adjustment (if equipped)
Your FOX shock has up to two External Damping Adjustments – rebound damping and compression
damping. Rebound damping controls how quickly the shock extends after hitting a bump – more
rebound damping means slower extension.
Compression damping controls how quickly the
shock compresses in response to a bump. More
compression damping means the shock is more
difficult to compress.
The blue knob at the lower end of the shock
absorber is the rebound adjuster and has
approximately 25 positions (see Figure 2). The
position of maximum rebound damping is when the Rebound Adjuster Knob
(Rotation shown is toward
knob is turned all the way up towards the main body maximum rebound damping)
of the shock until it stops. Do not attempt to force
the knob after it stops turning. To check the
WARNING
rebound damping setting, always count the number Jam Nut .430" (11 mm) Maximum
DO NOT EXCEED !!!
of clicks as you turn the knob to maximum
damping. For example, setting rebound damping “8
clicks out” means turning the rebound damping
knob all the way towards the shock body until it
stops, then turning it 8 clicks back.
Figure 2: Rebound adjuster and ride height
Default rebound damping setting: 10 clicks out
adjuster
The red knob on the reservoir is the compression damping knob and has 8 settings – with 1 being soft
and 8 being hard. The numbers line up with a notch on the reservoir.
Default compression damping setting: #3
Tuning Instructions
Now that you have the spring preload and shock length set correctly, it is time to tune the shock to your
liking. It is vital that the spring preload be set correctly before any damping changes are made –
otherwise you will be starting from a faulty baseline and will have difficulty getting the shock to work
properly.
Spring Preload
You might want to experiment with different sag settings to suit your own personal riding style. The
settings that you like will also change from bike to bike, and from track to track if you race. Also,
different tires make a difference in the settings that you prefer.
Try keeping a note book and experimenting with different set-ups; you will see differences in how your
bike steers: more rider sag will make it steer “slower”, less rider sag will make it steer “quicker”.
Ride Height / Shock Length Adjustment (if equipped)

The overall length of some FOX shocks can be adjusted. This adjustment changes the ride height and
can provide a useful tuning tool.

The main reasons to adjust ride height are to change the steering geometry of the motorcycle or to
change the ground clearance of the motorcycle. Raising the rear ride height steepens the steering head
angle; lowering the rear ride height slackens the steering head angle.
If the cornering clearance on your motorcycle is too low, increasing the rear ride height can reduce the
problem. On the other hand, you can lower the seat height by reducing the rear ride height.
NOTE: Most motorcycles were not designed with length-adjustable shocks in mind. Be careful when
changing the shock length. Make sure that moving parts like the wheel, swingarm, and fender do not
contact the motorcycle chassis at the limits of travel.
The handling of the motorcycle could be adversely affected by changing the rear ride height. Also,
decreasing rear ride height will reduce the cornering clearance of the motorcycle.
It is very important that you do not wind out the threaded adjuster more than is shown in Figure 2; do
not exceed 0.430 (11 mm) as there will not be enough threads left in the shock absorber and the results
could be disastrous.
The shock length may be adjusted while the shock is mounted to the motorcycle. To adjust, place the
bike on a stand so the wheel is in the air and the suspension is unloaded. Loosen the jam nut and turn
the extension. The eyelet or clevis at the lower end of the shock will remain stationary and the shaft will
rotate inside the shock. Be sure to take note of the above warnings.
Here are a few examples of how changing the rear ride height can affect your motorcycle performance:
Symptom Problem
Motorcycle is unstable at high speeds Rear Ride Height too high
Poor grip from rear tire Rear Ride Height too high
Unstable under heavy braking Rear Ride Height too high
Motorcycle understeers on exit corners Rear Ride Height too low
Difficult to change direction Rear Ride Height too low
Poor grip on front tire on exit corners Rear Ride Height too low
When to adjust Ride Height vs. Spring Preload
You may ask, “How is adjusting shock length different from adjusting spring preload? Don’t they both
affect ride height?” The answer – yes, they both affect ride height, but changing spring preload has
other side effects.
In a nutshell, spring preload only sets the amount of compression and extension travel available.
When you increase spring preload, you also increase the rear ride height, but at the cost of reduced rider
sag. Reducing rider sag will make your shock more likely to top out.
Similarly, reducing spring preload decreases rear ride height, but at the cost of increased rider sag.
Increasing rider sag will make your shock more likely to bottom out.
Changing ride height gives you independent control over ride height and travel. For example, suppose
you needed to increase the rear ride height to improve cornering clearance. On a stock shock absorber,
you would have no choice but to increase spring preload, making the shock top out more often and
decreasing ride quality. Changing the shock length could allow you to increase cornering clearance
while still maintaining proper travel.

Damping
Perfect damping control is as important as fine tuning your engine. Whether it comes to cutting precious
seconds off of your lap times or just obtaining a comfortable ride on a Sunday afternoon, FOX shocks
were especially designed to help achieve riding harmony.
The range of damping adjustment on a FOX shock is basically divided into two ranges: Internal and
External.
Internal adjustments can only be made by disassembling the shock absorber. This process is called “re-
valving”, because the internal valving of the shock is modified. The range of Internal Adjustment is
virtually unlimited. We at FOX Racing Shox have spent countless hours of Dyno, track and street
testing to give you a shock that just needs to be fine tuned to suit your personal riding style using the
external adjustments.
External adjustments can be made at any time and any place. Go out and ride! Focus on what the rear
of the bike is doing and not on going 110%. Sometimes you can feel it’s not quite right, for example,
but it may be hard to tell if the problem is too little rebound damping or too much compression damping.
Sometimes the different “feel” is subtle and you have to really concentrate to tell the difference. An
experienced friend watching you ride may be able to help. Try to develop a good “feel” for what is
going on. Once you get it right you will be glad you spent the time doing it.
Here is a list of the most common symptoms. It is a good idea to make one adjustment at a time and to
keep notes.

Summary of Damping Solutions
Adjustment Best For Testing Too much damping when… Too little damping when… "Perfect" when...
• Heavy enough to prevent wallowing or
Low Speed • small bumps Excess damping keeps the wheel from Similar symptoms to too much low speed
oscillation
Rebound • sweeper turns extending fast enough to follow the low spots rebound, except that the wheel is bouncing too
• Light enough to allow wheel to extend
Damping (blue • rippled surfaces between the small bumps. much.
fast enough to maintain good contact
knob) • wheel tends to hop on turns with small • Too much kicking up when braking hard
with ground.
bumps – especially washboard pavement going into a tight corner
• Bike tracks well on sweepers, brakes
• rear wheel skips too much when braking on • Bike wallows when exiting corners or in long,
well on washboard.
rippled pavement – does not develop good rolling dips in sweepers.
• Bike does not wallow when exiting
braking power
corners, but wheel maintains good
• poor rear wheel traction when accelerating
contact with ground.
over series of small bumps or rippled
• Bike feels stable in corners.
pavement
In general, suspension action seems well
controlled in these situations, but it just doesn’t
seem to develop good traction.
High Speed • Series of medium or Shock is “packing down”: Too much • Wheel kicks up when hitting large rolling- • Heavy enough to prevent rear end
Rebound large rolling-type damping keeps the wheel from extending enough type bumps at high speeds. kicking up or wallowing
Damping bumps on high- before you hit the next bump. • Light enough to prevent "packing
(requires speed sections • Suspension gets harsh over medium or large down" on series of bumps
valving change) • fast sections with rolling-type bumps at high speed. The first
deep rolling bumps few bumps in the series don’t feel bad, but
after that the suspension gets harsh and starts
jumping around.
Low Speed • small and medium • Shock seems to stay almost rigid, instead of • Shock bottoms out on medium-sized bumps. • Heavy enough to prevent bottoming
Compression rolling bumps absorbing bumps. • Rear end squats under acceleration. out on medium bumps
Damping • rippled pavement • Suspension is harsh over small bumps • Light enough to allow shock to stroke
(red knob) • Wheel skips when braking hard on rippled smoothly on small bumps
surfaces. • Light enough to avoid skipping when

braking on rippled surfaces
High Speed • Large bumps and • Suspension is harsh over pavement changes • Shock takes medium bumps smoothly, but • Heavy enough to prevent excess
Compression sharp-edged bumps • Shock stays too rigid and doesn’t use enough bottoms out too easily on larger bumps bottoming out
Damping • pavement changes travel to absorb bumps. • Shock bottoms out too easily on medium to • Light enough so shock strokes deeply
(requires • Shock rarely or never seems to bottom out big bumps to absorb these bumps without
even on the biggest bumps. harshness or rigidity
valving change)
10
Maintenance Checklist
Periodically inspect your FOX shock:
• Inspect the chrome shaft surface for damage or wear.
• Inspect the shaft seals for damage or wear. Oil should not normally be visible on the shock absorber shaft.
• Inspect the hose and hose fittings for damage or leakage. Make sure that the hose is not abrading any part of
the motorcycle.
Other Maintenance Considerations

• If riding in extreme conditions, service shock more frequently.
• Wash your shock with soap and water.
• Keep away from high pressure washers.
11

Yamaha FZR400 1988-90
Retail Price List Effective 2/1/01 Prices subject to change without notice
Bodywork: Sharkskinz Rear Sets: CFM 54-0400 $212.95

Part # for race Upper 59-4006 $145.00 Relocator Kit S&C 54-401 $54.95
bodywork Right Mid 59-4007 $65.00 ProTek N/A
Left Mid 59-4008 $65.00 Vortex N/A
Lower 1pc 59-4094 $215.00
SS Tail 59-4011 $160.00 Clip-ons: Graves 53-538 $154.95
Tank Cover 59-4012 $125.00 ProTek 53-038 $159.95
1 pc. Lower 59-4094 $215.00 Vortex 53-138 $149.95
Windscreen Zero Gravity Woodcraft 53-738 $149.95
Regular Clear 58-11500-01 $ 49.95
Regular Smoke 58-11500-02 $ 59.95 Chains:
Double Bubble Clear N/A Chain listed for 520 DID 41-520VM120 $109.33
Double Bubble Smoke N/A conversion 41-520ERV2120 $149.99
Colors Avbailable same price as smoke Stock chain EK 39-520MVX120 $108.31
Fairing 428 X 130 39-520MVX120G $124.62
Brackets: GP Tech N/A
Graves *C 36-FB-026 $154.95
Exhaust Sprockets: PBI 520
Systems: Front 38-PO91__ $17.95
Regular Position D&D 76-626390 $490.45 All sprockets for Rear 38-7150__ $41.95
Hindle N/A 520 conversion ProTek 520
M4 N/A Sprockets for stock Front 37-600__ $24.44
428 chain size Rear 37-4300__ $44.44
Jet Kits: Dynojet available Vortex 520
Stg. 1 50-4126 $122.22 Stock 19-55 Front N/A
Stg. 3 N/A Rear N/A
Factory
Config. 1.0 49-CRB-Y01-1.0 $89.95 Engine Covers: Factory Left N/A
Config. 1.7 N/A Right 49-COV-Y01-RHKT
Config. 3.0 49-CRB-Y01-3.0 $89.95 Tracksport 36-0941 $83.95
36-0962 $83.95
Air Filters: K&N
Stg. 1 71-YA4085 $31.16 Brake Pads: Front
Stg. 3 71-RC1824 $98.64 1988-89 EBC 22-FA88HH $33.33
BMC Ferodo 22-FDB337 $26.95
Race N/A 1990 EBC 22-FA123HH $33.33
Street N/A Ferodo 22-FDB666 $26.95
Brake lines: Goodridge *D 1991-92 EBC 22-FA252HH $33.33
Front (spiral wrap) 98-2100 $ 69.95 FZR400 RR Ferodo 22-FDB605 $26.95
(clear coat) 98-2100C $ 90.95 Perf.Friction 23-7520.95 $33.33
Rear (spiral wrap) 98-3817-2 $ 34.95 2 Sets required Other compounds available
(clear coat) 98-3817-2C $ 51.95
Frame Sliders: N/A
Rear Shock: Fox
Twin Clicker 97-12035 $580.00 Stands: Rear CFM Woodcraft 35-304 $111.00
TCR N/A Hindle 35-8 $99.95
Ohlins Pit Bull 35-0003 $120.00
N/A R&R 35-15 $88.89
Penske Front with Pin Stand # Pin #
8981 Call $725.00 CFM Woodcraft 35-300 35-321 $177.76
8987 Call $1,125.00 Pit Bull 35-0001 35-0001-50 $155.00
Fork Springs: Traxxion Dynamics Spools S&C 35-23_ $26.95

27-S3234_ $99.95 Add color to part#, Silver-1, Blue-3, Black-3, Violet-6, Red-7
Fork Valves: Race Tech 27-FEGVS3801 $139.95
Steering Damper: Brkt Kit S&C 12-1400 $52.95
* A Alum oval, Carbon round+oval, and Titanium oval available Front mount kit Damper 10-200 $123.00
* B Carbon oval, and Titanium oval available
* C this part # for stock inst cluster other tach mounts available Tire Warmers: Chicken Hawk 21-003 $ 425.00
* D -2lines, Carbo look, and colorflex lines available Tire Sox 21-006 $ 388.83
Street & Competition 800-326-5487

FZR400U
A1

CYLINDER HEAD
Ref. Part
No. Number Description Qty Remarks
1 1WG-11101-00-00 CYLINDER HEAD ASSEMBLY . 1

2 1WG-11133-10-00 . GUIDE, INTAKE VALVE . . . . . 16
3 93440-10153-00 . CIRCLIP . . . . . . . . . . . . . . . . . 16
4 99510-08016-00 . PIN, DOWEL ............. 12
5 90105-06384-00 . BOLT, WASHER BASED . . . . 23
6 90338-08174-00 . PLUG . . . . . . . . . . . . . . . . . . . 12
7 90340-12112-00 . PLUG, STRAIGHT SCREW . . . 6
8 90116-06437-00 . BOLT, STUD ............. 8
9 90201-087K2-00 WASHER, PLATE . . . . . . . . . . . 12
10 90179-08530-00 NUT . . . . . . . . . . . . . . . . . . . . . 12
11 NGK-CR8E0-00-00 PLUG, SPARK (NGK-R CR8E) . 4
12 1WG-11181-00-00 GASKET, CYLINDER HEAD 1 . 1
13 1WG-11191-00-00 COVER, CYLINDER.HEAD 1 .. 1
14 1WG-11193-00-00 GASKET, HEAD COVER 1 . . . . 1
15 90109-064F0-00 BOLT . . . . . . . . . . . . . . . . . . . . 8
16 90209-11262-00 WASHER . . . . . . . . . . . . . . . . . 8
17 2GH-1111G-00-00 RUBBER, MOUNT 1 . . . . . . . . . 8
FZR400U
A2

CYLINDER
Ref. Part
1 1WG-11310-00-00 CYLINDER . . . . . . . . . . . . . . . . 1
2 93210-60737-00 O-RING .................. 4
3 99510-12016-00 PIN, DOWEL .............. 2
4 3TJ-11351-00-00 GASKET, CYLINDER . . . . . . . . 1
5 90153-06045-00 SCREW, HEXAGON . . . . . . . . . 2
6 90430-06014-00 GASKET ................. 2
FZR400U
A3

CRANKSHAFT-PISTON
Ref. Part
1 99999-01963-00 CRANKSHAFT . . . . . . . . . . . . . 1
2 93101-26156-00 OIL SEAL . . . . . . . . . . . . . . . . . 1
3 1WG-11416-00-00 PLANE BEARING,
CRANKSHAFT 1 . . . . . . . . . . . 12 UR BLUE
1WG-11416-10-00 PLANE BEARING,
CRANKSHAFT 1 . . . . . . . . . . . 12 UR BLACK
CRANKSHAFT 1 . . . . . . . . . . . 12 UR BROWN
CRANKSHAFT 1 . . . . . . . . . . . 12 UR GREEN
CRANKSHAFT 1 . . . . . . . . . . . 12 UR YELLOW
4 1WG-11631-01-00 PISTON STD .............. 4 UR STD
1WG-11636-01-00 PISTON 2 O/S 0. 0 . . . . . . . . . . 4 ALT. PART
1WG-11638-01-00 PISTON 4 O/S 1. 0 . . . . . . . . . . 4 ALT. PART
5 1WG-11610-00-00 PISTON RING SET . . . . . . . . . . 4 UR STD
1WG-11610-20-00 PISTON RING SET (2ND O/S) . 4 ALT. PART
1WG-11610-40-00 PISTON RING SET (4TH O/S) . . 4 ALT. PART
6 1WG-11633-01-00 PIN, PISTON .............. 4
7 93450-16068-00 CIRCLIP . . . . . . . . . . . . . . . . . . 8
8 1WG-11650-00-00 CONNECTING ROD
ASSEMBLYASSY . . . . . . . . . . . 4
9 1WG-11654-00-00 . BOLT, CONNECTING ROD .. 2
10 90179-07531-00 . NUT . . . . . . . . . . . . . . . . . . . . 2
11 1WG-11656-00-00 PLANE BEARING,
CONNECTING ROD . . . . . . . . . 8 UR BLUE
CONNECTING ROD . . . . . . . . . 8 UR BLAKC
CONNECTING ROD . . . . . . . . . 8 UR BROWN
CONNECTING ROD . . . . . . . . . 8 UR GREEN
FZR400U
A4

CAMSHAFT-CHAIN
Ref. Part
1 3BF-12171-00-00 CAMSHAFT 1 . . . . . . . . . . . . . . 1
2 3BF-12181-00-00 CAMSHAFT 2 . . . . . . . . . . . . . . 1
3 1WG-12176-00-00 SPROCKET, CAM CHAIN . . . . . 2
4 90105-07385-00 BOLT, WASHER BASED . . . . . 4
5 94590-95112-00 CHAIN BF04MA . . . . . . . . . . . . 1
6 94690-95021-00 . MASTER LINK . . . . . . . . . . . . 1
7 1WG-12241-00-00 GUIDE, STOPPER 2 . . . . . . . . . 1
8 99999-01903-00 TENSNRASSEMBLY CAM
CLTCAM CHAIN . . . . . . . . . . . . 1
9 4BE-12213-00-00 GASKET, TENSIONER CASE . . 1
10 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
11 1WG-12251-00-00 DAMPER, CHAIN 1 ......... 1
12 1WG-12252-00-00 DAMPER, CHAIN 2 ......... 1
13 90109-065A8-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
FZR400U
A5

VALVE
Ref. Part
1 1WG-12111-00-00 VALVE, INTAKE . . . . . . . . . . . . 8

2 1WG-12121-00-00 VALVE, EXHAUST . . . . . . . . . . 8
3 1WG-12116-00-00 SEAT, VALVE SPRING . . . . . . . 16
4 1WG-12113-01-00 SPRING, VALVE INNER . . . . . . 16
5 1WG-12117-00-00 RETAINER, VALVE SPRING .. 16
6 1WG-12118-00-00 COTTER, VALVE . . . . . . . . . . . 32
7 1WG-12119-00-00 SEAL, VALVE STEM ........ 16
8 1WG-12153-09-00 LIFTER, VALVE (O/S) . . . . . . . . 16 UR GREEN
1WG-12153-21-00 LIFTER, VALVE . . . . . . . . . . . . 16 UR BLUE
1WG-12153-30-00 LIFTER, VALVE
(1WG-12153-31-00) . . . . . . . . . . 16 UR RED
9 1HX-12168-00-00 PAD, ADJUSTING 2 (1.20) . . . . 16 UR
1HX-12168-20-00 PAD, ADJUSTING 2 (1.25) . . . . 16 UR
1HX-12168-A0-00 PAD, ADJUSTING 2 (1.45) . . . . 16 UR
1HX-12168-F0-00 PAD, ADJUSTING 2 (1.50) . . . . 16 UR
1HX-12168-H1-00 PAD, ADJUSTING 2 (1.55) . . . . 16 UR
1HX-12168-K1-00 PAD, ADJUSTING 2 (1.60) . . . . 16 UR
1HX-12168-M1-00 PAD, ADJUSTING 2 (1.65) . . . . 16 UR
1HX-12168-R1-00 PAD, ADJUSTING 2 (1.70) . . . . 16 UR
1HX-12168-U1-00 PAD, ADJUSTING 2 (1.75) . . . . 16 UR
1HX-12168-W1-00 PAD, ADJUSTING 2 (1.80) . . . . 16 UR
1HX-12168-Y1-00 PAD, ADJUSTING 2 (1.85) . . . . 16 UR
CONTINUED ON NEXT FRAME ➤
FZR400U
A6

VALVE
Ref. Part
9 1HX-12169-90-00 PAD, ADJUSTING 2 (2.10) . . . . 16 UR

1HX-12169-E0-00 PAD, ADJUSTING 2 (2.15) . . . . 16 UR
1HX-12169-G0-00 PAD, ADJUSTING 2 (2.20) . . . . 16 UR
1HX-12169-J0-00 PAD, ADJUSTING 2 (2.25) . . . . 16 UR
1HX-12169-L0-00 PAD, ADJUSTING 2 (2.30) . . . . 16 UR
1HX-12169-N0-00 PAD, ADJUSTING 2 (2.35) . . . . 16 UR
1HX-12169-T0-00 PAD, ADJUSTING 2 (2.40) . . . . 16 UR
FZR400U
A7

WATER PUMP
Ref. Part
1 1WG-12420-00-00 WATER PUMP ASSEMBLY . . . 1

2 1WG-12439-00-00 . O-RING ................. 1
3 93210-33133-00 O-RING .................. 1
4 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
5 91316-06035-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
6 1WG-12481-00-00 PIPE 1 . . . . . . . . . . . . . . . . . . . 1
7 93210-21190-00 O-RING .................. 2
8 91316-06012-00 BOLT, SOCKET HEAD . . . . . . . 2
9 1WG-12446-01-00 JOINT ................... 1
10 93210-17746-00 O-RING .................. 2
11 91316-06040-00 BOLT, SOCKET HEAD . . . . . . . 3
12 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
13 1WG-12482-00-00 PIPE 2 . . . . . . . . . . . . . . . . . . . 1
14 1WG-12483-00-00 PIPE 3 . . . . . . . . . . . . . . . . . . . 1
15 93210-15566-00 O-RING .................. 2
16 91316-06012-00 BOLT, SOCKET HEAD . . . . . . . 2
17 1WG-12576-00-00 HOSE 1 . . . . . . . . . . . . . . . . . . 1
18 1WG-12577-00-00 HOSE 2 . . . . . . . . . . . . . . . . . . 1
19 46X-12410-00-00 THERMOSTAT ASSEMBLY . . . 1
20 1WG-12417-00-00 HOUSING, THERMOSTAT . . . . 1
21 1WG-12413-01-00 COVER, THERMOSTAT . . . . . . 1
22 91316-06020-00 BOLT, SOCKET HEAD . . . . . . . 2
23 95826-06020-00 BOLT, flange (95806-06020-00) 1
24 1WG-12579-00-00 HOSE, 4 . . . . . . . . . . . . . . . . . . 1
25 90450-32051-00 HOSE CLAMP ASSEMBLY ... 2
FZR400U
A8

RADIATOR-HOSE
Ref. Part
1 1WG-12461-00-00 RADIATOR ASSEMBLY . . . . . . 1

2 1WG-12405-00-00 BLOWER ASSEMBLY ....... 1
3 1AA-12630-00-00 . MOTOR ASSEMBLY ....... 1
4 1UF-12611-00-00 . FAN . . . . . . . . . . . . . . . . . . . . 1
5 98580-05010-00 . SCREW, PAN HEAD ....... 3
6 92901-05600-00 . WASHER, PLATE . . . . . . . . . . 3
7 90119-06044-00 . BOLT, WITH WASHER . . . . . . 3
8 1AA-12535-00-00 . PLATE . . . . . . . . . . . . . . . . . . 3
9 2TK-12590-00-00 CONDUCTION ASSEMBLY ... 1
10 22W-12462-00-00 . CAP, RADIATOR . . . . . . . . . . 1
11 95816-06016-00 BOLT, FLANGE . . . . . . . . . . . . 2
13 46X-12498-00-00 PROTECTOR . . . . . . . . . . . . . . 1
14 98506-05010-00 SCREW, PAN HEAD ........
15 92906-05100-00 WASHER, SPRING . . . . . . . . . . 4
16 92906-05600-00 WASHER, PLATE . . . . . . . . . . . 4
17 90183-05024-00 NUT, SPRING . . . . . . . . . . . . . . 4
18 90445-096E8-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
19 90467-08003-00 CLIP .................... 2
20 90338-20188-00 PLUG . . . . . . . . . . . . . . . . . . . . 1
21 90480-15483-00 GROMMET . . . . . . . . . . . . . . . . 2
22 90387-07390-00 COLLAR ................. 1
23 90387-074W0-00 COLLAR ................. 1
24 95816-06025-00 BOLT, FLANGE . . . . . . . . . . . . 2
25 1WG-12578-00-00 HOSE 3 . . . . . . . . . . . . . . . . . . 1
26 1WG-12588-00-00 HOSE 5 . . . . . . . . . . . . . . . . . . 1
27 1WG-12484-00-00 PIPE 4 . . . . . . . . . . . . . . . . . . . 1
28 90153-06045-00 . SCREW, HEXAGON . . . . . . . . 1
29 90430-06014-00 . GASKET ................ 1
FZR400U
A9

RADIATOR-HOSE
Ref. Part
30 93210-21190-00 O-RING .................. 1

31 91316-06012-00 BOLT, SOCKET HEAD . . . . . . . 1
32 90110-06142-00 BOLT, HEXAGON SOCKET
HEAD . . . . . . . . . . . . . . . . . . . . 1
FZR400U
A10

OIL PUMP
Ref. Part
1 1WG-13330-01-00 PUMP SHAFT ASSEMBLY . . . . 1

2 1WG-13316-00-00 COVER, PUMP . . . . . . . . . . . . . 1
3 90201-113K2-00 WASHER, PLATE . . . . . . . . . . . 1
4 93603-17070-00 PIN, DOWEL .............. 1
5 1WG-13310-00-00 ROTOR ASSEMBLY 1 . . . . . . . 1
6 93603-09106-00 PIN, DOWEL .............. 2
7 1WG-13336-00-00 HOUSING, ROTOR . . . . . . . . . . 1
8 97801-06020-00 SCREW, PAN HEAD ........ 1
9 99510-08012-00 PIN, DOWEL .............. 1
10 1WG-13329-00-00 GASKET, PUMP COVER . . . . . 1
HEAD . . . . . . . . . . . . . . . . . . . . 3
12 1WG-13412-00-00 HOUSING, STRAINER . . . . . . . 1
13 4H7-13411-02-00 STRAINER, OIL . . . . . . . . . . . . 1
14 3YX-13415-00-00 SEAL, OIL STRAINER . . . . . . . 1
15 90110-06099-00 BOLT, HEX SKT HEADSOCKET
HEAD . . . . . . . . . . . . . . . . . . . . 2
FZR400U
A11

OIL FILTER
Ref. Part
1 4H7-13447-00-00 COVER, OIL ELEMENT ...... 1

2 1L9-13340-01-00 BY-PASS VALVE ASSEMBLY . 1
3 93210-16629-00 . O-RING ................. 1
4 93210-87723-00 O-RING .................. 1
5 90501-20422-00 SPRING, COMPRESSION . . . . . 1
6 90201-21608-00 WASHER, PLATE . . . . . . . . . . . 1
7 1L9-13441-11-00 ELEMENT, OIL CLNR . . . . . . . . 1
8 90480-23193-00 . GROMMET . . . . . . . . . . . . . . . 2
9 11H-13490-00-00 RELIEF VALVE ASSEMBLY . . . 1
10 93210-10096-00 O-RING .................. 1
11 1WG-13417-00-00 COVER, STRAINER . . . . . . . . . 1
12 3HE-13414-10-00 GASKET, STRAINER COVER . . 1
13 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 14
14 99510-08016-00 PIN, DOWEL .............. 2
15 3VD-13455-00-00 PLUG . . . . . . . . . . . . . . . . . . . . 1
16 214-11198-01-00 GASKET ................. 1
17 90465-10306-00 CLAMP .................. 1
18 1WG-13161-00-00 PIPE, DELIVERY 1 . . . . . . . . . . 1
19 91316-06012-00 BOLT, SOCKET HEAD . . . . . . . 1
20 90401-10106-00 BOLT, UNION ............. 2
21 90430-10171-00 GASKET ................. 4
FZR400U
A12

AIR FILTER
Ref. Part
1 1WG-13586-00-00 JOINT, CARBURETOR 1 . . . . . 2 2

2 1WG-13596-00-00 JOINT, CARBURETOR 2 . . . . . 2 4
3 1WG-13597-00-00 JOINT, CARB 3 . . . . . . . . . . . . 4
4 93210-32738-00 O-RING .................. 4
5 16G-13569-00-00 PLUG, BLIND . . . . . . . . . . . . . . 4
6 90467-10039-00 CLIP .................... 4
7 91316-06020-00 BOLT, SOCKET HEAD . . . . . . . 8
9 1WG-14411-01-00 CASE, AIR CLEANER 1 . . . . . . 1
10 1WG-14421-00-00 CASE, AIR CLEANER 2 . . . . . . 1
11 1VJ-14462-00-00 SEAL . . . . . . . . . . . . . . . . . . . . 1
12 97780-50125-00 SCREW, TAPPING . . . . . . . . . . 11
13 1WG-14451-00-00 ELEMENT, AIR CLEANER . . . . 1
14 1WG-14412-00-00 CAP, CLEANER CASE 1 . . . . . 1
15 5T0-14457-00-00 SEAL . . . . . . . . . . . . . . . . . . . . 1
16 1WG-14453-00-00 JOINT, AIR CLNR 1 . . . . . . . . . 4
17 90460-56287-00 CLAMP, HOSE . . . . . . . . . . . . . 4
18 90445-11452-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
19 90467-10008-00 CLIP .................... 3
20 4X7-2149Y-00-00 FILTER ASSEMBLY . . . . . . . . . 1
21 90445-115E8-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
22 98580-05016-00 SCREW, PAN HEAD ........ 4
23 92901-05600-00 WASHER, PLATE . . . . . . . . . . . 4
24 90464-10075-00 CLAMP .................. 1
FZR400U
B1

CARBURETOR
Ref. Part
1 3FH-14901-00-00 CARBURETOR ASSEMBLY 1 . 1

2 3BF-14902-00-00 CARBURETOR ASSEMBLY 2 . 1
5 1WG-14940-00-00 . DIAPHRAGM ASSEMBLY ... 1
6 3BF-1490J-00-00 . NEEDLE SET . . . . . . . . . . . . . 1
7 1WG-14141-90-00 . NOZZLE, MAIN ........... 1
8 12R-14105-00-00 . PILOT SCREW SET . . . . . . . . 1
9 620-1423A-68-00 . JET, MAIN (#87.5) ......... 1
10 3H1-14142-15-00 . JET, PILOT (#15) . . . . . . . . . . 1
11 3CF-14107-12-00 . NEEDLE VALVE SET . . . . . . . 1
12 137-14153-00-00 . WASHER, MAIN JET . . . . . . . 1
13 1AE-14565-00-00 . SCREW . . . . . . . . . . . . . . . . . 1
14 256-14997-00-00 . SEAL . . . . . . . . . . . . . . . . . . . 2
15 1A8-14953-00-00 . WASHER . . . . . . . . . . . . . . . . 1
16 1WG-14147-00-00 . O’’RING . . . . . . . . . . . . . . . . . 1
17 1AE-14237-00-00 . GASKET ................ 1
18 1AE-14261-00-00 . HOLDER ................ 1
19 1AE-14227-00-00 . O-RING ................. 1
20 98580-05010-00 . SCREW, PAN HEAD ....... 4
21 3H5-14933-00-00 . SPRING, DIAPHRAGM . . . . . . 1
22 (3BF-14103-00-00) THROTTLE SCREW SET . . . . . 1
23 1HX-1410A-00-00 . STARTER SET . . . . . . . . . . . . 1
24 98511-04012-00 . SCREW, PAN HEAD ....... 4 4 (2 PCS FOR #2)
25 98503-04014-00 . SCREW, PAN HEAD ....... 2
26 12R-14191-00-00 . PLUG, DRAIN ............ 1
27 1FN-14565-00-00 . SCREW . . . . . . . . . . . . . . . . . 1
28 353-14186-00-00 . PIN, FLOAT . . . . . . . . . . . . . . 1
29 1WG-14985-00-00 . FLOAT . . . . . . . . . . . . . . . . . . 1
FZR400U
B2

CARBURETOR
Ref. Part
30 830-14231-26-00 . JET, PILOT AIR #1 0 . . . . . . . 1

31 3F9-14118-00-00 . CAP . . . . . . . . . . . . . . . . . . . . 1
32 1WG-1490L-00-00 STARTER LEVR SET, 1 . . . . . . 1
33 1WG-1490K-10-00 STOP SCREW SET ......... 3
34 98580-05010-00 SCREW, PAN HEAD ........ 16
35 1WG-14251-00-00 NIPPLE .................. 2
36 36Y-14147-00-00 O-RING .................. 12
37 1AE-14197-00-00 PIPE .................... 2
38 1FN-14918-00-00 RING . . . . . . . . . . . . . . . . . . . . 2
39 1HX-14197-00-00 PIPE .................... 1
40 1HX-14251-00-00 NIPPLE .................. 1
41 1HX-14148-00-00 PIPE .................... 1
FZR400U
B3

EXHAUST
Ref. Part
1 3BF-14710-00-00 MUFFLER ASSEMBLY L . . . . . 1

2 90101-06576-00 . BOLT . . . . . . . . . . . . . . . . . . . 1
3 92906-06600-00 . WASHER . . . . . . . . . . . . . . . . 1
4 90179-06500-00 NUT . . . . . . . . . . . . . . . . . . . . . 8
5 3YF-14613-01-00 GASKET, EXHAUST PIPE . . . . 4
6 95816-08020-00 BOLT, FLANGE . . . . . . . . . . . . 1
7 90179-08639-00 NUT, SPEC’’L SHAPE (30) . . . . 1
FZR400U
B4

CRANKCASE
Ref. Part
1 1WG-15100-01-00 CRANKCASE ASSEMBLY . . . . 1

2 11H-15138-00-00 . NOZZLE 1 . . . . . . . . . . . . . . . 4
3 99510-12016-00 . PIN, DOWEL ............. 3
4 1HX-15138-00-00 . NOZZLE 1 . . . . . . . . . . . . . . . 1
5 93210-12152-00 . O-RING ................. 1
6 371-11167-01-00 . PIPE, BREATHER 2 . . . . . . . . 1
7 36Y-15189-00-00 . PLUG . . . . . . . . . . . . . . . . . . . 2
8 93210-16629-00 . O-RING ................. 2
9 2H7-15361-00-00 . GAUGE, LEVEL . . . . . . . . . . . 1
10 90201-237K5-00 . WASHER, PLATE . . . . . . . . . . 1
11 93315-32516-00 . BEARING . . . . . . . . . . . . . . . . 1
12 90116-08486-00 BOLT, STUD .............. 2
13 90116-08487-00 BOLT, STUD .............. 10
15 90201-087K3-00 WASHER, PLATE . . . . . . . . . . . 12
16 95816-06040-00 BOLT . . . . . . . . . . . . . . . . . . . . 10
17 95816-06050-00 BOLT, FLANGE . . . . . . . . . . . . 5
18 95816-06070-00 BOLT, FLANGE . . . . . . . . . . . . 3
19 95816-06080-00 BOLT, FLANGE . . . . . . . . . . . . 1
20 95816-06090-00 BOLT, FLANGE . . . . . . . . . . . . 2
21 95816-08070-00 BOLT, FLANGE . . . . . . . . . . . . 1
22 90430-06166-00 GASKET ................. 1
23 90465-10307-00 CLAMP .................. 1
24 90465-10308-00 CLAMP .................. 1
25 (1WG-11165-00-00) PLATE, BREATHER . . . . . . . . . 1
26 98580-06012-00 SCREW, PAN HEAD ........ 2
27 (1WG-11145-00-00) PLATE, BREATHER 2 ....... 1
28 98580-06012-00 SCREW, PAN HEAD ........ 4
29 1WG-11166-00-00 PIPE, BREATHER 1 . . . . . . . . . 1
FZR400U
B5

CRANKCASE
Ref. Part
30 90467-14015-00 CLIP .................... 2

31 90445-116E9-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
32 90465-06289-00 CLAMP .................. 1
33 90467-10038-00 CLIP .................... 1
34 1WG-15381-00-00 PLATE, BEARING COVER . . . . 1
35 91316-06012-00 BOLT, SOCKET HEAD . . . . . . . 2
FZR400U
B6

CRANKCASE COVER
Ref. Part
1 1WG-15411-00-00 COVER, CRANKCASE L ..... 1

2 1L9-15417-00-00 COVER, CAP . . . . . . . . . . . . . . 1
3 1WG-15316-00-00 DAMPER, ENGINE MOUNT 1 . . 1
4 1WG-15427-00-00 COVER, CAP 2 ............ 1
5 98901-05008-00 SCREW, BIND . . . . . . . . . . . . . 4
6 3HE-15451-10-00 GASKET, CRANKCASE
COVER 1 . . . . . . . . . . . . . . . . . 1
7 1UF-15467-00-00 GASKET ................. 1
8 99510-08016-00 PIN, DOWEL .............. 2
HEAD . . . . . . . . . . . . . . . . . . . . 4
HEAD . . . . . . . . . . . . . . . . . . . . 1
11 1WG-15421-00-00 COVER, CRANKCASE R . . . . . 1
COVER 2 . . . . . . . . . . . . . . . . . 1
13 99510-08016-00 PIN, DOWEL .............. 2
14 91311-06025-00 BOLT, SOCKET HEAD . . . . . . . 2
15 91311-06035-00 BOLT, SOCKET HEAD . . . . . . . 4
16 91311-06045-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
17 1WG-15431-02-00 COVER, CRANKCASE 3 ..... 1
18 1WG-15425-00-00 COVER, GENERATOR 2 ..... 1
19 1WG-15326-00-00 DAMPER, ENGINE MOUNT 2 . . 1
20 98901-05008-00 SCREW, BIND . . . . . . . . . . . . . 4
COVER 3 . . . . . . . . . . . . . . . . . 1
22 99510-08016-00 PIN, DOWEL .............. 2
23 91311-06025-00 BOLT, SOCKET HEAD . . . . . . . 8
24 91311-06035-00 BOLT, SOCKET HEAD . . . . . . . 2
25 3F9-15362-00-00 PLUG, OIL LEVEL . . . . . . . . . . 1
FZR400U
B7

CRANKCASE COVER
Ref. Part
26 93210-27778-00 O-RING .................. 1

27 1WG-15410-00-00 CRCS COVER ASSEMBLY
LASSEMBLY 1 . . . . . . . . . . . . . 1
28 1WG-15416-00-00 . COVER, OIL PUMP ........ 1
29 1WG-15449-00-00 . RING, RUBBER . . . . . . . . . . . 1
30 1JK-15486-00-00 . GROMMET . . . . . . . . . . . . . . . 2
31 90209-05279-00 . WASHER . . . . . . . . . . . . . . . . 2
32 98580-05010-00 . SCREW, PAN HEAD ....... 2
33 1WG-15455-00-00 GASKET 1 . . . . . . . . . . . . . . . . 1
34 99510-08016-00 PIN, DOWEL .............. 2
35 91311-06025-00 BOLT, SOCKET HEAD . . . . . . . 3
36 91311-06035-00 BOLT, SOCKET HEAD . . . . . . . 2
FZR400U
B8

GENERATOR
Ref. Part
1 3FH-81450-10-00 ROTOR ASSEMBLY . . . . . . . . . 1

2 3FH-81410-10-00 STATOR ASSEMBLY . . . . . . . . 1
3 90110-06138-00 BOLT, HEX SKT HEAD ...... 3
4 98580-05016-00 SCREW, PAN HEAD ........ 2
5 92990-05100-00 WASHER, SPRING . . . . . . . . . . 2
6 92901-05600-00 WASHER, PLATE . . . . . . . . . . . 2
7 90280-03047-00 KEY, WOODRUFF . . . . . . . . . . 1
9 90201-107K6-00 WASHER, PLATE . . . . . . . . . . . 1
FZR400U
B9

STARTING MOTOR
Ref. Part
1 1WG-81800-61-00 STARTING MOTOR

ASSEMBLYASSY . . . . . . . . . . . 1
2 1HX-81815-00-00 . CORD, STARTER MOTOR . . . 1
3 25G-81826-00-00 . BOLT . . . . . . . . . . . . . . . . . . . 1
4 1WG-81820-01-00 . REAR BRACKET ASSEMBLY. 1
5 5H0-81844-01-00 . GASKET ................ 2
6 5H0-81847-01-00 . O-RING ................. 1
7 95023-06020-00 BOLT, FLANGE . . . . . . . . . . . . 2
FZR400U
B10

STARTER CLUTCH
Ref. Part
1 1WG-15521-00-00 SHAFT 1 ................. 1

2 1WG-15512-00-00 GEAR, IDLER 1 . . . . . . . . . . . . 1
3 1WG-15517-00-00 GEAR, IDLER 2 . . . . . . . . . . . . 1
4 4H7-15521-00-00 SHAFT 1 ................. 2
5 1WG-15570-00-00 STARTER CLUTCH
ASSEMBLYASSY . . . . . . . . . . . 1
6 1WG-15515-00-00 GEAR 3 . . . . . . . . . . . . . . . . . . 1
7 90280-16053-00 KEY, WOODRUFF . . . . . . . . . . 1
8 90201-107K6-00 WASHER, PLATE . . . . . . . . . . . 1
10 93306-20005-00 BEARING (B6200) . . . . . . . . . . 1
FZR400U
B11

CLUTCH
Ref. Part
1 1WG-16150-01-00 PRI DRVN GEARGEAR COMP . 1

2 1WG-16154-00-00 PLATE, THRUST 1 . . . . . . . . . . 1
3 1WG-16371-01-00 BOSS, CLUTCH . . . . . . . . . . . . 1
4 21V-16321-00-00 PLATE, FRICTION . . . . . . . . . . 8
5 131-16324-00-00 PLATE, CLUTCH 1 . . . . . . . . . . 7
6 37F-16351-00-00 PLATE, PRESSURE 1 ....... 1
7 90501-227E0-00 SPRING, COMPRESSION . . . . . 5
8 90119-05001-00 BOLT, WITH WASHER . . . . . . . 5
9 1WG-16356-00-00 ROD, PUSH 1 . . . . . . . . . . . . . . 1
10 93210-48364-00 O-RING .................. 1
11 90215-18225-00 WASHER, LOCK ........... 1
12 90170-18221-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
13 93109-08058-00 OIL SEAL (SD07 8-21-5.5 HS) . 1
14 1WG-16357-01-00 ROD, PUSH 2 . . . . . . . . . . . . . . 1
15 93505-16006-00 BALL . . . . . . . . . . . . . . . . . . . . 1
16 1WG-16340-01-00 PUSH LEVER ASSEMBLY . . . . 1
17 1WG-16304-00-00 BALL SCREW HOUSING
ASSEMBLY . . . . . . . . . . . . . . . 1
18 90113-08021-00 BOLT, SET . . . . . . . . . . . . . . . . 1
19 90179-08179-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
20 90506-09232-00 SPRING, TENSION . . . . . . . . . . 1
21 90157-05065-00 SCREW, PAN HEAD ........ 2
22 132-16346-00-00 HOOK, SPRING . . . . . . . . . . . . 1
23 90387-212R3-00 COLLAR ................. 1
24 1WG-16164-00-00 PLATE, THRUST 2 . . . . . . . . . . 1
25 1WG-16181-00-00 SPACER 1 . . . . . . . . . . . . . . . . 1
26 93310-345R8-00 BEARING . . . . . . . . . . . . . . . . . 1
FZR400U
B12

TRANSMISSION
Ref. Part
1 1WG-17411-00-00 AXLE, MAIN . . . . . . . . . . . . . . . 1

2 1WG-17151-00-00 GEAR, 5TH PINION . . . . . . . . . 1
3 90209-18208-00 WASHER . . . . . . . . . . . . . . . . . 1
4 93410-22039-00 CIRCLIP . . . . . . . . . . . . . . . . . . 1
5 3EN-17131-00-00 GEAR, 3RD PINION (21T/23T) . 1
6 1WG-17161-00-00 GEAR, 6TH PINION . . . . . . . . . 1
7 1WG-17121-01-00 GEAR, 2ND PINION . . . . . . . . . 1
8 93306-37205-00 BEARING (83B285C3) . . . . . . . 1
9 93440-54152-00 CIRCLIP . . . . . . . . . . . . . . . . . . 1
10 93399-99933-00 BEARING . . . . . . . . . . . . . . . . . 1
11 278-17425-00-00 CIRCLIP 2 . . . . . . . . . . . . . . . . 1
12 1WG-17421-01-00 AXLE, DRIVE . . . . . . . . . . . . . . 1
13 93306-30550-00 BEARING . . . . . . . . . . . . . . . . . 1
14 1WG-17221-00-00 GEAR, 2ND WHEEL . . . . . . . . . 1
15 90209-27192-00 WASHER . . . . . . . . . . . . . . . . . 1
16 93440-30077-00 CIRCLIP . . . . . . . . . . . . . . . . . . 1
17 1WG-17261-00-00 GEAR, 6TH WHEEL . . . . . . . . . 1
18 1WG-17231-00-00 GEAR, 3RD WHEEL . . . . . . . . . 1
19 3EN-17241-00-00 GEAR, 4TH WHEEL . . . . . . . . . 1
20 90209-22191-00 WASHER . . . . . . . . . . . . . . . . . 1
21 93440-25084-00 CIRCLIP . . . . . . . . . . . . . . . . . . 1
22 1WG-17251-00-00 GEAR, 5TH WHEEL . . . . . . . . . 1
23 1WG-17211-00-00 GEAR, 1ST WHEEL . . . . . . . . . 1
24 90387-252R2-00 COLLAR ................. 1
25 93102-35109-00 OIL SEAL (SD-35-62-6 HS) . . . . 1
26 3FH-17460-00-00 SPROCKET, DRIVE 19T . . . . . . 1
27 90215-21022-00 WASHER, LOCK ........... 1
28 90179-18020-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
29 90201-20276-00 WASHER, PLATE (1.0T) . . . . . . 1
FZR400U
C1

TRANSMISSION
Ref. Part
30 93311-42045-00 BEARING (20NG3315NE) . . . . . 1

31 278-17424-01-00 CIRCLIP 1 . . . . . . . . . . . . . . . . 1
32 278-17425-00-00 CIRCLIP 2 . . . . . . . . . . . . . . . . 1
33 4G0-17433-01-00 NOZZLE . . . . . . . . . . . . . . . . . . 1
FZR400U
C2

SHIFT CAM-FORK
Ref. Part
1 1WG-18540-01-00 SHIFT CAM ASSEMBLY . . . . . . 1

2 90501-06022-00 . SPRING, COMPRESSION . . . . 1
3 278-18542-00-00 . POINT, NEUTRAL ......... 1
4 278-18566-00-00 . PLATE, SIDE 2 . . . . . . . . . . . . 1
5 98701-05012-00 . SCREW, FLAT HEAD . . . . . . . 1
6 1WG-18531-01-00 BAR, SHIFT FORK GUIDE 1 . . . 1
7 1WG-18535-01-00 BAR, SHIFT FORK GUIDE 2 . . . 1
8 1WG-18511-00-00 FORK, SHIFT 1 ............ 1
9 1WG-18512-00-00 FORK, SHIFT 2 ............ 1
10 1WG-18513-00-00 FORK, SHIFT 3 ............ 1
11 1WG-18536-00-00 STOPPER, SHIFT BAR . . . . . . . 1
12 1HX-18127-00-00 STOPPER, SCREW ......... 1
13 90508-23707-00 SPRING, TORSION ......... 1
14 1WG-18562-00-00 PLATE, STOPPER 2 . . . . . . . . . 1
15 36Y-18140-00-00 STOPPER LEVER ASSEMBLY . 1
16 50W-21631-00-00 BOLT 1 .................. 1
17 95811-06016-00 BOLT, FLANGE (95822-06016) . 2
FZR400U
C3

SHIFT SHAFT
Ref. Part
1 3EN-18101-01-00 SHIFT SHAFT ASSEMBLY . . . . 1

2 90508-32682-00 . SPRING, TORSION ........ 1
3 93102-12321-00 OIL SEAL, SD-TYPE ........ 1
4 90560-12211-00 SPACER ................. 1
5 93109-12053-00 OIL SEAL (SDO 12/18/4-1) . . . . 2
6 3HE-18110-00-00 SHIFT PEDAL ASSEMBLY . . . . 1
7 132-18113-01-00 . COVER, SHIFT PEDAL . . . . . . 1
8 1WG-18112-01-00 ARM, SHIFT . . . . . . . . . . . . . . . 1
9 2H9-18154-00-00 . COVER, DUST . . . . . . . . . . . . 1
10 97011-06020-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
11 1WG-18115-00-00 ROD, SHIFT . . . . . . . . . . . . . . . 1
12 90170-06228-00 NUT (COUNTER CLOCKWISE) 1
13 95380-06700-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
FZR400U
C4

FRAME
Ref. Part
1 3FH-21110-00-00 FRAME .................. 1

2 1WG-21277-00-00 SHEET 3 ................. 1
3 1WG-21268-00-00 SEAL . . . . . . . . . . . . . . . . . . . . 1
4 1WG-2143A-00-00 CAP . . . . . . . . . . . . . . . . . . . . . 2
5 1WG-21190-00-35 FRAME, REAR . . . . . . . . . . . . . 1 SILVER
6 3FH-21140-00-35 TUBE, DOWN . . . . . . . . . . . . . . 1 SILVER
7 1WG-21150-00-35 DOWN TUBE COMP 2 . . . . . . . 1 SILVER
8 91021-12030-00 BOLT, FLANGE . . . . . . . . . . . . 4
9 90201-120K4-00 WASHER, PLATE . . . . . . . . . . . 4
10 91316-10030-00 BOLT, SOCKET HEAD . . . . . . . 2
11 95701-10500-00 NUT, FLANGE (95702-10500) . . 2
13 95701-10500-00 NUT, FLANGE (95702-10500) . . 4
14 91311-08025-00 BOLT, SOCKET HEAD . . . . . . . 4
15 95811-10080-00 BOLT, FLANGE . . . . . . . . . . . . 2
16 91011-10295-00 BOLT, FLANGE . . . . . . . . . . . . 1
17 91011-10165-00 BOLT, FLANGE . . . . . . . . . . . . 1
18 1WG-21427-00-00 BRACKET, REAR LWR 1 . . . . . 1
19 95303-12600-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
20 92990-12200-00 WASHER, PLAIN . . . . . . . . . . . 1
21 92901-12100-00 WASHER, SPRING . . . . . . . . . . 1
22 95701-10500-00 NUT, FLANGE (95702-10500) . . 4
23 1WG-21459-00-00 SPACER ................. 2
24 1WG-2142M-00-00 BRACKET, RADIATOR 3 . . . . . 1
25 91012-06016-00 BOLT, FLANGE (1WG) . . . . . . . 1
26 1WG-21147-00-00 BRACKET, AIR CLEANR . . . . . 1
27 90387-062M9-00 COLLAR ................. 1
28 90201-06067-00 WASHER, PLATE . . . . . . . . . . . 1
29 1WG-21148-00-00 BRACKET, AIR CLEANR . . . . . 1
FZR400U
C5

FRAME
Ref. Part
30 91012-06016-00 BOLT, FLANGE (1WG) . . . . . . . 4

31 90480-18171-00 GROMMET . . . . . . . . . . . . . . . . 1
32 1WG-2137Y-00-00 GUIDE, AIR . . . . . . . . . . . . . . . 1
33 1WG-2139R-00-00 COVER 2 . . . . . . . . . . . . . . . . . 1
34 90183-05003-00 NUT, SPRING . . . . . . . . . . . . . . 5
35 1WG-2139W-00-00 COVER .................. 1
36 95702-06600-00 NUT, FLANGE . . . . . . . . . . . . . 2
37 1WG-2137W-00-00 SCOOP, AIR 1 . . . . . . . . . . . . . 1
38 1WG-2137X-00-00 SCOOP, AIR 2 . . . . . . . . . . . . . 1
39 1WG-2139U-00-00 DAMPER 2 . . . . . . . . . . . . . . . . 2
40 90119-06093-00 BOLT, WITH WASHER . . . . . . . 2
41 90387-06681-00 COLLAR ................. 1
42 1WG-2117M-00-00 COVER 2 . . . . . . . . . . . . . . . . . 4
43 1WG-2117N-00-00 COVER 3 . . . . . . . . . . . . . . . . . 2
44 1WG-2117U-00-00 COVER 6 . . . . . . . . . . . . . . . . . 1
45 1WG-2119G-00-00 EMBLEM 3 . . . . . . . . . . . . . . . . 1
46 1WG-2119H-00-00 EMBLEM 4 . . . . . . . . . . . . . . . . 1
FZR400U
C6

FENDER
Ref. Part
1 3FH-21510-00-GE FENDER, FRONT . . . . . . . . . . . 1 SILKY WHITE

2 1KH-21717-00-00 . DAMPER, SIDE COVER
(4N0-24181-00-00) . . . . . . . . . 2
3 46X-2313A-00-00 BRACE, FORK . . . . . . . . . . . . . 1
5 1A8-21518-00-00 HOLDER, CABLE . . . . . . . . . . . 1
6 3FH-25875-00-00 HOLDER, BRAKE HOSE 1 . . . . 1
7 3FH-25876-00-00 HOLDER, BRAKE HOSE 2 . . . . 1
8 95023-06025-00 BOLT, FLANGE . . . . . . . . . . . . 2
9 3BF-21611-00-00 FENDER, REAR . . . . . . . . . . . . 1
10 90480-11391-00 GROMMET . . . . . . . . . . . . . . . . 1
11 91026-06012-00 BOLT, FLANGE (1VJ) ....... 4
12 31A-14477-00-00 PLATE . . . . . . . . . . . . . . . . . . . 4
13 4N0-28186-00-00 POUCH .................. 1
14 4K5-2814E-10-00 HOOK ................... 2
15 3BF-W2162-00-00 MUD GUARD . . . . . . . . . . . . . . 1
16 116-82131-00-00 BAND, BATTERY . . . . . . . . . . . 1
17 1WG-W2810-00-00 TOOL KIT ................ 1
FZR400U
C7

SIDE COVER
Ref. Part
1 1WG-Y2171-00-GE COVER SIDE 1 . . . . . . . . . . . . . 1 SILKY WHITE

2 36Y-28346-00-00 . MOLD 2 . . . . . . . . . . . . . . . . . 1
3 90480-18495-00 . GROMMET . . . . . . . . . . . . . . . 2
4 1WG-21781-00-00 . EMBLEM 1 . . . . . . . . . . . . . . . 2
5 1WG-2173E-01-00 . GRAPHIC . . . . . . . . . . . . . . . . 1
6 1WG-2173F-01-00 . GRAPHIC . . . . . . . . . . . . . . . . 1
7 1WG-2174G-01-00 . GRAPHIC 3 . . . . . . . . . . . . . . 1
8 1WG-2174H-01-00 . GRAPHIC 4 . . . . . . . . . . . . . . 1
9 1WG-2174J-00-00 . GRAPHIC 5 . . . . . . . . . . . . . . 1
10 1WG-2174K-00-00 . GRAPHIC 6 . . . . . . . . . . . . . . 1
11 1WG-21788-00-00 . GRAPHIC . . . . . . . . . . . . . . . . 1
12 1WG-21789-00-00 . GRAPHIC . . . . . . . . . . . . . . . . 1
13 1WG-21737-00-00 . EMBLEM . . . . . . . . . . . . . . . . 1
14 14T-21773-00-00 . GROMMET . . . . . . . . . . . . . . . 1
15 1WG-21717-00-00 . DAMPER (1UY-21747-00-00) . 2
16 90159-06033-00 SCREW, WITH WASHER . . . . . 2
17 90387-113R1-00 COLLAR ................. 2
HEAD . . . . . . . . . . . . . . . . . . . . 2
19 90480-01401-00 GROMMET . . . . . . . . . . . . . . . . 4
20 1WG-2177G-00-00 BOX, BATTERY . . . . . . . . . . . . 1
21 90480-22362-00 GROMMET . . . . . . . . . . . . . . . . 1
22 90480-14229-00 GROMMET . . . . . . . . . . . . . . . . 2
23 90387-07391-00 COLLAR ................. 2
24 31A-14477-00-00 PLATE . . . . . . . . . . . . . . . . . . . 2
25 90119-06097-00 BOLT, WITH WASHER . . . . . . . 2
26 120-82131-00-00 BAND, BATTERY . . . . . . . . . . . 1
27 1WG-21871-00-00 TANK, RECOVERY ......... 1
28 4L0-21875-00-00 CAP . . . . . . . . . . . . . . . . . . . . . 1
FZR400U
C8

SIDE COVER
Ref. Part
29 1AA-21874-00-00 GASKET ................. 1

30 3GM-21816-00-00 PIPE 1 . . . . . . . . . . . . . . . . . . . 1
32 34X-21691-00-00 FLAP . . . . . . . . . . . . . . . . . . . . 1
33 3BF-21683-80-00 PLATE, SPEC ............. 1
FZR400U
C9

SWING ARM
Ref. Part
1 3FH-22110-00-00 REAR ARM ............... 1

2 33M-22184-00-00 BUSH . . . . . . . . . . . . . . . . . . . . 1
3 93320-32403-00 BEARING . . . . . . . . . . . . . . . . . 2
4 47X-22129-00-00 COVER, THRUST 2 ......... 2
5 90201-161J2-00 WASHER, PLATE . . . . . . . . . . . 2
6 93317-21746-00 BEARING . . . . . . . . . . . . . . . . . 2
7 93109-17048-00 OIL SEAL (SDO 17-24-4) . . . . . 2
8 90387-122R5-00 COLLAR ................. 1
9 1WG-21151-00-00 UNAVAILABLE IN PRICE BOOK 1
10 90387-06681-00 COLLAR ................. 2
11 90149-06011-00 SCREW . . . . . . . . . . . . . . . . . . 2
12 1WG-22310-00-00 CHAIN CASE ASSEMBLY . . . . 1
14 46X-22141-00-00 SHAFT, PIVOT . . . . . . . . . . . . . 1
15 90201-14740-00 WASHER, PLATE . . . . . . . . . . . 1
16 90185-14070-00 NUT, SELF-LOCKING . . . . . . . . 1
17 (1WG-2217A-00-00) ARM, RELAY . . . . . . . . . . . . . . 1
18 93317-31701-00 BEARING . . . . . . . . . . . . . . . . . 1
19 93317-21746-00 BEARING . . . . . . . . . . . . . . . . . 2
20 93109-17048-00 OIL SEAL (SDO 17-24-4) . . . . . 4
21 90387-102R4-00 COLLAR ................. 1
22 90387-122R5-00 COLLAR ................. 1
23 93399-99919-00 BEARING . . . . . . . . . . . . . . . . . 1
24 93101-16131-00 OIL SEAL . . . . . . . . . . . . . . . . . 2
25 90387-124L0-00 COLLAR ................. 1
26 1WG-2217M-00-00 ARM 1 . . . . . . . . . . . . . . . . . . . 2
28 90101-10658-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
29 90101-10659-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
FZR400U
C10

SWING ARM
Ref. Part
30 90201-10774-00 WASHER, PLATE . . . . . . . . . . . 1

31 90201-101J1-00 WASHER, PLATE . . . . . . . . . . . 3
32 95611-10100-00 NUT, U . . . . . . . . . . . . . . . . . . . 4
33 2GH-25875-50-00 HOLDER, BRKE HOSE 1 . . . . . 1
34 98580-06020-00 SCREW . . . . . . . . . . . . . . . . . . 1
35 92995-06100-00 WASHER, SPRING . . . . . . . . . . 1
FZR400U
C11

REAR SHOCKS
Ref. Part
1 3FH-22210-00-00 SHK/ABS ASSEMBLY,

REARASSEMBLY, REAR . . . . . 1
2 90387-124T2-00 COLLAR ................. 1
3 90109-10554-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
4 90201-101J1-00 WASHER, PLATE . . . . . . . . . . . 1
5 95601-10100-00 NUT, U (95602-10100-00) . . . . . 1
FZR400U
C12

FRONT FORK
Ref. Part
1 1WG-23102-00-00 FRONT FORK ASSEMBLY L

(L.H) . . . . . . . . . . . . . . . . . . . . 1
2 1WG-23126-00-00 . TUBE, OUTER 1 . . . . . . . . . . . 1
3 122-23129-00-00 . . GASKET, DRAIN PLUG . . . . 1
4 4H7-23119-00-00 . . PLUG, DRAIN -
(122-23119-01) . . . . . . . . . . . . 1
5 3R4-23153-00-00 . RING, SNAP . . . . . . . . . . . . . . 1
6 3EN-23145-00-00 . OIL SEAL . . . . . . . . . . . . . . . . 1
7 2YK-23125-00-00 . METAL, SLIDE 1 .......... 1
8 3EN-23144-00-00 . SEAL, DUST ............. 1
9 4V2-23146-L0-00 . WASHER, OIL SEAL ....... 1
10 3BF-23110-50-00 . INNER TUBE COMP. 1 . . . . . . 1
11 1WG-23170-00-00 . CYLINDER, FRTFRKFRONT
FORK . . . . . . . . . . . . . . . . . . 1
12 (3R4-23173-L0-00) SPINDLE, TAPER . . . . . . . . . . . 1
13 1WG-23141-00-00 . SPRING, FRONT FORK . . . . . 1
14 2K8-23158-L0-00 . GASKET ................ 1
15 3EN-23111-00-00 . BOLT, CAP .............. 1
16 1FK-23142-00-00 . SEAT, SPRING UPPER ..... 1
17 1W4-23114-L0-00 . GASKET ................ 1
18 3R4-23181-L0-00 . BOLT, HEX SCKT
HEADSOCKET HEAD ...... 1
19 1WG-23118-00-00 . SPACER ................ 1
20 1WG-23103-00-00 FRONT FORK ASSEMBLY R
(R.H) . . . . . . . . . . . . . . . . . . . . 1
21 1WG-23136-00-00 . TUBE, OUTER 2 . . . . . . . . . . . 1
22 122-23129-00-00 . . GASKET, DRAIN PLUG . . . . 1
23 4H7-23119-00-00 . . PLUG, DRAIN -
(122-23119-01) . . . . . . . . . . . . 1
24 3R4-23153-00-00 . RING, SNAP . . . . . . . . . . . . . . 1
25 3EN-23145-00-00 . OIL SEAL . . . . . . . . . . . . . . . . 1
FZR400U
D1

FRONT FORK
Ref. Part
26 2YK-23125-00-00 . METAL, SLIDE 1 .......... 1

27 3EN-23144-00-00 . SEAL, DUST ............. 1
28 4V2-23146-L0-00 . WASHER, OIL SEAL ....... 1
29 3BF-23110-50-00 . INNER TUBE COMP. 1 . . . . . . 1
30 1WG-23170-00-00 . CYLINDER, FRTFRKFRONT
FORK . . . . . . . . . . . . . . . . . . 1
31 (3R4-23173-L0-00) SPINDLE, TAPER . . . . . . . . . . . 1
32 1WG-23141-00-00 . SPRING, FRONT FORK . . . . . 1
33 2K8-23158-L0-00 . GASKET ................ 1
34 3EN-23111-00-00 . BOLT, CAP .............. 1
35 1FK-23142-00-00 . SEAT, SPRING UPPER ..... 1
36 1W4-23114-L0-00 . GASKET ................ 1
37 3R4-23181-L0-00 . BOLT, HEX SCKT
HEADSOCKET HEAD ...... 1
38 91311-08040-00 . BOLT, SOCKET HEAD . . . . . . 1
39 1WG-23118-00-00 . SPACER ................ 1
40 90201-08085-00 . WASHER, PLATE . . . . . . . . . . 1
41 1WG-23340-00-00 UNDER BRACKET COMP. . . . . 1
42 2NX-23356-00-00 BOLT 2 .................. 2
43 93332-00001-00 BEARING . . . . . . . . . . . . . . . . . 1
FZR400U
D2

STEERING
Ref. Part
1 93332-00008-00 BEARING . . . . . . . . . . . . . . . . . 1
2 3EN-23415-00-00 COVER, BALL RACE 1 ...... 1
3 90179-25033-00 NUT . . . . . . . . . . . . . . . . . . . . . 2
4 90202-26142-00 WASHER, PLATE . . . . . . . . . . . 1
5 26H-23418-01-00 WASHER, SPECIAL . . . . . . . . . 1
6 90176-22050-00 NUT, CROWN ............. 1
7 1WG-23435-00-00 CROWN, HANDLE . . . . . . . . . . 1
8 91609-40210-00 . PIN, SPRING . . . . . . . . . . . . . 2
9 91316-08030-00 BOLT, SOCKET HEAD . . . . . . . 2
10 1WG-2317E-00-00 STAY . . . . . . . . . . . . . . . . . . . . 1
FZR400U
D3

FUEL TANK
Ref. Part
1 1WG-24110-01-00 FUEL TANK . . . . . . . . . . . . . . . 1

2 1HX-24181-00-00 DAMPER, LOCATING 1 . . . . . . 2
3 90387-06380-00 COLLAR ................. 1
4 95811-06080-00 BOLT, FLANGE . . . . . . . . . . . . 1
5 (1WG-21346-00-00) BRACKET, TANK FTNG . . . . . . 2
6 95811-06016-00 BOLT, FLANGE (95822-06016) . 4
7 1WG-21345-00-00 BRACKET, TANK FITTING . . . . 1
8 95811-08016-00 BOLT, FLANGE . . . . . . . . . . . . 2
9 1HX-24182-00-00 DAMPER, LOCATING 2 . . . . . . 2
10 90465-13169-00 CALMP .................. 2
11 1WG-21348-00-00 BRACKT, TANK FITTING . . . . . 1
12 95811-06016-00 BOLT, FLANGE (95822-06016) . 2
13 1WG-24185-00-00 DAMPER, LOCATING 5 . . . . . . 1
14 1WG-24602-00-00 CAP ASSEMBLY . . . . . . . . . . . 1
15 1WG-24500-00-00 FUEL COCK ASSEMBLY 1 ... 1
16 4X8-24534-00-00 . SEAL, COCK . . . . . . . . . . . . . 1
17 4X8-24512-00-00 . O-RING ................. 1
18 98580-03008-00 . SCREW, PAN HEAD ....... 2
19 1WG-24524-00-00 LEVER, COCK . . . . . . . . . . . . . 1
20 98606-04016-00 SCREW, OVAL HEAD ....... 1
21 90202-05187-00 WASHER, PLATE . . . . . . . . . . . 2
22 90149-06011-00 SCREW . . . . . . . . . . . . . . . . . . 2
23 1FK-24560-00-00 FILTER ASSEMBLY . . . . . . . . . 1
24 26H-24568-00-00 BAND, FILTER . . . . . . . . . . . . . 1
25 1WG-24566-00-00 BRACKET, FILTER ......... 1
26 1WG-24398-01-00 BAND 1 . . . . . . . . . . . . . . . . . . 1
27 1WG-24491-01-00 BRACKET, FUEL PUMP . . . . . . 1
28 98906-05014-00 SCREW, BIND . . . . . . . . . . . . . 3
29 90480-14229-00 GROMMET . . . . . . . . . . . . . . . . 1
FZR400U
D4

FUEL TANK
Ref. Part
30 90387-07391-00 COLLAR ................. 1

31 90179-06500-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
32 90480-11454-00 GROMMET . . . . . . . . . . . . . . . . 1
33 1WG-24311-00-00 PIPE, FUEL 1 . . . . . . . . . . . . . . 1
34 1WG-24312-00-00 PIPE 2 . . . . . . . . . . . . . . . . . . . 1
35 90467-10091-00 CLIP, SCISSOR . . . . . . . . . . . . 2
36 90467-11044-00 CLIP .................... 2
37 1WG-W217A-00-0X COVER, TOP . . . . . . . . . . . . . . 1 SILKY WHITE/ FINE
RED
38 99224-00040-00 . EMBLEM, YAMAHA YAMAHA
(BLACK) . . . . . . . . . . . . . . . . 2
39 3FH-24364-00-00 STAY . . . . . . . . . . . . . . . . . . . . 1
40 3BF-24158-00-00 STAY, FUEL TANK 2 . . . . . . . . 1
41 95811-06012-00 BOLT, FLANGE . . . . . . . . . . . . 2
43 90154-06040-00 SCREW, BINDING . . . . . . . . . . 2
45 1WG-2414H-00-00 TRIM, COVER PANEL ....... 2
46 90387-112R6-00 COLLAR ................. 2
47 90149-06246-00 SCREW, SPEC’’L SHAPE .... 2
48 90480-18495-00 GROMMET . . . . . . . . . . . . . . . . 2
49 90387-112R6-00 COLLAR ................. 2
50 90201-06697-00 WASHER, PLATE . . . . . . . . . . . 2
51 98511-06025-00 SCREW PAN HEAD
(92501-06025) . . . . . . . . . . . . . 2
52 1WG-24614-00-00 PLATE, CAP .............. 1
HEAD . . . . . . . . . . . . . . . . . . . .
54 1WG-24665-00-00 DAMPER . . . . . . . . . . . . . . . . . 3
HEAD . . . . . . . . . . . . . . . . . . . . 3
FZR400U
D5

FUEL TANK
Ref. Part
56 90201-06067-00 WASHER, PLATE . . . . . . . . . . . 3

57 95380-06600-00 NUT . . . . . . . . . . . . . . . . . . . . . 3
HEAD . . . . . . . . . . . . . . . . . . . . 2
59 1WG-2414A-00-00 COVER, FILLER . . . . . . . . . . . . 1
60 1WG-24622-00-00 WASHER, RING . . . . . . . . . . . . 2
61 90560-03220-00 SPACER ................. 1
62 90445-070F1-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
63 1WG-13907-00-00 FUEL PUMP COMP. . . . . . . . . . 1
64 90445-126E7-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
65 90460-12256-00 CLAMP, HOSE . . . . . . . . . . . . . 2
FZR400U
D6

SEAT
Ref. Part
2 1WG-24711-00-00 . COVER, SINGLE SEAT ..... 1

3 116-24741-00-00 . PAD, SEAT .............. 1
4 1T4-24741-00-00 . PAD, SEAT .............. 1
5 1WG-24750-00-00 TANDEM SEAT ASSEMBLY . . . 1
6 1WG-24751-00-00 COVER, TANDEM SEAT ..... 1
7 1WG-24723-00-00 . DAMPER, SEAT . . . . . . . . . . . 1
8 95701-06500-00 . NUT, FLANGE . . . . . . . . . . . . 3
9 46X-24754-00-00 . HOOK, SEAT . . . . . . . . . . . . . 1
10 4L0-24712-11-00 . PLATE . . . . . . . . . . . . . . . . . . 2
11 47X-24739-00-00 . BOLT, SEAT FITTING ...... 2
12 90468-10056-00 . CLIP ................... 2
13 2AX-24705-00-00 SEAT LOCK ASSEMBLY . . . . . 1
14 95811-06010-00 BOLT, FLANGE . . . . . . . . . . . . 2
15 26H-21308-00-00 HELMET HANGER ASSEMBLY
(4R8-21308-00) . . . . . . . . . . . . . 1
16 90149-06154-00 SCREW . . . . . . . . . . . . . . . . . . 1
FZR400U
D7

FRONT WHEEL
Ref. Part
1 1WG-25168-00-UA WHEEL, CAST FRONT . . . . . . . 1 CAST WHEEL WHITE

2 90560-15314-00 SPACER ................. 1
3 93306-30202-00 BEARING . . . . . . . . . . . . . . . . . 2
4 93102-22014-00 OIL SEAL . . . . . . . . . . . . . . . . . 1
5 341-25149-00-00 CLUTCH, METER . . . . . . . . . . . 1
6 341-25846-00-00 RETAINER, CLUTCH . . . . . . . . 1
7 93105-45017-00 OIL SEAL . . . . . . . . . . . . . . . . . 1
8 94111-170T6-00 110/70-R17 BS 53HCY03A) ... 1 BRIDGESTONE
9 93900-00030-00 VALVE, RIM . . . . . . . . . . . . . . . 1 TAIHEIYO
10 29L-25398-00-00 BALANCER, WHEEL (10G) ... 1 UR
29L-25398-10-00 BALANCER, WHEEL (20G) ... 1 UR
11 1WG-25190-00-00 GEAR UNIT ASSEMBLY ..... 1
12 42X-25181-00-00 AXLE, WHEEL . . . . . . . . . . . . . 1
13 90387-15550-00 COLLAR ................. 1
FZR400U
D8

FRONT BRAKE CALIPER
Ref. Part
1 1WG-25830-02-00 DISC BRAKE ASSEMBLY. . . . . 2

2 90109-08718-00 BOLT . . . . . . . . . . . . . . . . . . . . 12
3 1WG-25810-01-00 CALIPER ASSEMBLY RIGHT . . 1
4 31A-W0057-00-00 . PISTON ASSEMBLY, CALIPER 2
5 31A-W0047-00-00 . . CALIPER SEAL KIT . . . . . . . 1
6 26H-W0045-11-00 . BRAKE PAD KIT . . . . . . . . . . 1
7 1WG-25919-00-00 . SUPPORT, PAD . . . . . . . . . . . 1
8 3HE-25924-00-00 . PIN, PAD . . . . . . . . . . . . . . . . 2
9 3HE-25925-00-00 . CLIP ................... 2
10 1J3-W0048-00-00 . BLEED SCREW KIT . . . . . . . . 1
11 51J-25836-00-00 . COVER, DUST . . . . . . . . . . . . 1
12 1WG-25810-11-00 CALIPER ASSEMBLY LEFT . . . 1
13 31A-W0057-00-00 . PISTON ASSEMBLY, CALIPER 2
14 31A-W0047-00-00 . . CALIPER SEAL KIT . . . . . . . 1
15 26H-W0045-11-00 . BRAKE PAD KIT . . . . . . . . . . 1
16 1WG-25919-00-00 . SUPPORT, PAD . . . . . . . . . . . 1
17 3HE-25924-00-00 . PIN, PAD . . . . . . . . . . . . . . . . 2
18 3HE-25925-00-00 . CLIP ................... 2
19 1J3-W0048-00-00 . BLEED SCREW KIT . . . . . . . . 1
20 51J-25836-00-00 . COVER, DUST . . . . . . . . . . . . 1
FZR400U
D9

REAR WHEEL
Ref. Part
1 1WG-25338-00-UA WHEEL, CAST REAR . . . . . . . . 1 CAST WHEEL WHITE

2 93306-30309-00 BEARING . . . . . . . . . . . . . . . . . 1
3 93306-20310-00 BEARING . . . . . . . . . . . . . . . . . 1
4 93102-25044-00 OIL SEAL . . . . . . . . . . . . . . . . . 1
5 90387-173M5-00 COLLAR ................. 1
6 1KT-25364-00-00 DAMPER . . . . . . . . . . . . . . . . . 6
7 94114-180T7-00 140/60-R18 BS 64H64H CY04A) 1 BRIDGESTONE
8 93900-00030-00 VALVE, RIM . . . . . . . . . . . . . . . 1 TAIHEIYO
9 29L-25398-00-00 BALANCER, WHEEL (10G) ... 1 UR
10 1KT-25366-03-00 CLUTCH, HUB . . . . . . . . . . . . . 1 LOW GLOSS BLK
11 93306-20446-00 BEARING . . . . . . . . . . . . . . . . . 1
12 93102-28022-00 OIL SEAL . . . . . . . . . . . . . . . . . 1
13 90387-172J8-00 COLLAR ................. 1
14 1HX-25455-20-00 SPROCKET, DRIVN 55T . . . . . . 1 YAMAHA BLK
15 95601-08200-00 NUT, U . . . . . . . . . . . . . . . . . . . 6
16 90116-08498-00 BOLT, STUD .............. 6
17 94581-22130-00 CHAIN DID Y28HVS
(D.I.D. 428HVS-130LE) . . . . . . . 1
18 1WG-25388-00-00 PULLER, CHAIN 1 . . . . . . . . . . 2
19 90101-08647-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
20 95333-08600-00 NUT . . . . . . . . . . . . . . . . . . . . . 6
21 1KT-22174-00-00 END 1 ................... 2
22 92901-08600-00 WASHER . . . . . . . . . . . . . . . . . 2
23 1WG-25371-00-00 BAR, TENSION ............ 1
24 2GH-25876-00-00 HOLDER, BRKE HOSE 2 . . . . . 1
25 97011-06010-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
26 92995-06100-00 WASHER, SPRING . . . . . . . . . . 1
FZR400U
D10

REAR WHEEL
Ref. Part

28 95701-08500-00 NUT, FLANGE . . . . . . . . . . . . . 2
29 91490-20020-00 PIN, COTTER . . . . . . . . . . . . . . 2
30 3FH-25381-00-00 AXLE, WHEEL . . . . . . . . . . . . . 1
31 90201-177K7-00 WASHER, PLATE . . . . . . . . . . . 2
32 90387-172R7-00 COLLAR ................. 1
33 90387-173L5-00 COLLAR ................. 1
34 90171-16024-00 NUT, CASTLE ............. 1
35 91401-30030-00 PIN, COTTER . . . . . . . . . . . . . . 1
FZR400U
D11

REAR BRAKE CALIPER
Ref. Part
1 1WG-25831-50-00 DISC, BRAKE ............. 1

2 90109-08718-00 BOLT . . . . . . . . . . . . . . . . . . . . 3
3 1WG-25810-51-00 CALIPER ASSEMBLY ....... 1
4 51L-W0057-00-00 . PISTON ASSEMBLY, CALIPER 1
5 51L-W0047-11-00 . . CALIPER SEAL KIT . . . . . . . 1
6 51L-25919-00-00 . SUPPORT, PAD . . . . . . . . . . . 1
7 51L-W0046-02-00 . BRAKE PAD KIT 2 . . . . . . . . . 1
8 51L-25924-00-00 . PIN PAD ................ 2
9 51L-W0048-00-00 . BLEED SCREW KIT . . . . . . . . 2
10 1WG-25819-00-00 BRACKET, CALIPER . . . . . . . . 1
FZR400U
D12

HANDLEBAR-CABLE
Ref. Part
1 2TK-26121-00-00 HANDLEBAR LH . . . . . . . . . . . 1
2 2TK-26122-00-00 HANDLEBAR RH . . . . . . . . . . . 1
3 91316-08030-00 BOLT, SOCKET HEAD . . . . . . . 2
4 91316-08025-00 BOLT, SOCKET HEAD . . . . . . . 2
5 341-23469-00-00 CAP, BOLT ............... 4
6 1WG-26111-00-00 HANDLEBAR . . . . . . . . . . . . . . 1
7 1WG-26246-00-00 END, GRIP . . . . . . . . . . . . . . . . 1
8 1WG-26112-00-00 BAR, HANDLE . . . . . . . . . . . . . 1
9 1KG-26241-00-00 GRIP (LEFT) .............. 1
10 3FH-26240-00-00 GRIP ASSEMBLY . . . . . . . . . . . 1
11 3FH-26311-00-00 CABLE, THROTTLE 1 ....... 1
12 3FH-26312-00-00 CABLE, THROTTLE 2 ....... 1
13 5H0-26393-00-00 HOLDER ................. 1
14 98506-05008-00 SCREW, PAN HEAD ........ 1
15 1WG-26335-00-00 CABLE, CLUTCH . . . . . . . . . . . 1
16 90179-08316-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
17 90123-08083-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
18 1WG-26331-00-00 CABLE, STARTER 1 ........ 1
19 1WG-83940-00-00 STARTER ASSEMBLY . . . . . . . 1
20 1WG-83941-00-00 . LEVER, STARTER . . . . . . . . . 1
21 1WG-28357-00-00 . STAY 2 ................. 1
22 1WG-83942-00-00 . COVER, STARTER . . . . . . . . . 1
23 98906-03006-00 . SCREW, BIND . . . . . . . . . . . . 2
24 90209-10131-00 . WASHER . . . . . . . . . . . . . . . . 1
25 98906-06008-00 . SCREW, BIND . . . . . . . . . . . . 1
26 91006-06020-00 BOLT, FLANGE (2GU) . . . . . . . 1
FZR400U
E1

FRONT MASTER CYLINDER
Ref. Part
1 36Y-25850-01-00 MASTER CYLINDER

ASSEMBLY . . . . . . . . . . . . . . . 1
2 36Y-25852-01-00 . CAP, RESERVOIR . . . . . . . . . 1
3 98706-04012-00 . SCREW, FLAT HEAD . . . . . . . 2
4 36Y-25854-00-00 . DIAPHRAGM, RESERVOIR .. 1
5 36Y-W0041-00-00 . CYLINDER KIT, MASTER . . . . 1
6 36Y-25867-00-00 BRACKET, MASTER CYLINDER 1
7 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
8 92906-06100-00 WASHER, SPRING . . . . . . . . . . 2
9 4L0-25862-00-00 BOOT, MASTER CYLINDER . . . 1
10 3HE-25872-01-00 HOSE, BRAKE 1 ........... 1
11 1WG-25873-01-00 HOSE, BRAKE 2 ........... 2
12 1J7-25885-01-00 JOINT ................... 1
13 91316-06025-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
14 90401-10095-00 BOLT, UNION ............. 1
15 90401-10096-00 BOLT, UNION ............. 4
16 90201-10118-00 WASHER, PLATE . . . . . . . . . . . 11
17 90338-09012-00 PLUG . . . . . . . . . . . . . . . . . . . . 1
FZR400U
E2

STAND-FOOTREST
Ref. Part
1 2KT-27311-00-00 STAND, SIDE . . . . . . . . . . . . . . 1

2 90109-10474-00 BOLT . . . . . . . . . . . . . . . . . . . . 1
3 90185-10037-00 NUT, SELF-LOCKING . . . . . . . . 1
4 90506-18224-00 SPRING, TENSION . . . . . . . . . . 1
5 90506-26225-00 SPRING, TENSION . . . . . . . . . . 1
6 1TX-27351-00-00 GUIDE, SIDE STAND . . . . . . . . 1
7 2KT-27315-00-00 LINK, SIDE STAND ......... 1
8 1WG-27410-00-00 FRT FOOTREST ASSEMBLY
LASSEMBLY (L) . . . . . . . . . . . 1
9 2GH-27413-00-00 . COVER, FOOTREST ....... 1
10 90157-05079-00 . SCREW, PAN HEAD ....... 2
11 90109-082A4-00 . BOLT . . . . . . . . . . . . . . . . . . . 1
12 1WG-27420-00-00 FRT FOOTREST ASSEMBLY
RASSEMBLY (R) . . . . . . . . . . . 1
13 2GH-27413-00-00 . COVER, FOOTREST ....... 1
14 90157-05079-00 . SCREW, PAN HEAD ....... 2
15 90109-082A4-00 . BOLT . . . . . . . . . . . . . . . . . . . 1
16 46X-27442-01-00 BRACKET 2 . . . . . . . . . . . . . . . 1
17 46X-27443-01-00 BRACKET 3 . . . . . . . . . . . . . . . 1
18 90109-103A9-00 BOLT . . . . . . . . . . . . . . . . . . . . 2
19 90206-17084-00 WASHER, WAVE . . . . . . . . . . . 2
HEAD . . . . . . . . . . . . . . . . . . . . 4
21 1WG-27445-01-00 PLATE 1 ................. 1
22 1WG-27446-01-00 PLATE 2 ................. 1
23 1WG-27425-00-00 BRACKET, FOOTREST 2 . . . . . 1
25 1HX-27431-00-00 FOOTREST, REAR 1 . . . . . . . . 1
26 1HX-27441-00-00 FOOTREST, REAR 2 . . . . . . . . 1
FZR400U
E3

STAND-FOOTREST
Ref. Part
28 93501-04011-00 BALL . . . . . . . . . . . . . . . . . . . . 2
29 1HX-27437-00-00 WASHER, SPECIAL . . . . . . . . . 2
30 91701-06040-00 PIN, CLEVIS . . . . . . . . . . . . . . . 2
31 91490-20020-00 PIN, COTTER . . . . . . . . . . . . . . 2
32 90387-064H8-00 COLLAR ................. 2
33 1WG-2741L-00-00 BRACKET 4 . . . . . . . . . . . . . . . 1
34 1WG-2742L-00-00 BRACKET 5 . . . . . . . . . . . . . . . 1
35 1HX-27415-00-00 PLATE, FOOTREST . . . . . . . . . 2
36 95811-08035-00 BOLT, FLANGE (95821-08035) . 4
FZR400U
E4

REAR MASTER CYLINDER
Ref. Part
1 1WG-27200-00-00 PEDAL, BRAKE . . . . . . . . . . . . 1

2 90506-20377-00 SPRING, TENSION . . . . . . . . . . 1
3 1WG-25850-50-00 MASTER CYLINDER
ASSEMBLY . . . . . . . . . . . . . . . 1
4 1WG-W0042-50-00 . CYLINDER KIT, MASTER . . . . 1
5 36Y-2582A-50-00 . JOINT .................. 1
6 93210-15620-00 . O-RING ................. 1
7 98511-04012-00 . SCREW, PAN HEAD ....... 1
8 92901-04100-00 . WASHER, SPRING . . . . . . . . . 1
9 92901-04600-00 . WASHER, PLATE . . . . . . . . . . 1
10 92016-08030-00 SCREW . . . . . . . . . . . . . . . . . . 2
11 31A-27222-00-00 JOINT ................... 1
12 95303-08700-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
13 90240-08013-00 PIN, CLEVIS . . . . . . . . . . . . . . . 1
14 90201-08083-00 WASHER, PLATE . . . . . . . . . . . 1
15 91490-20020-00 PIN, COTTER . . . . . . . . . . . . . . 1
16 31A-25894-01-00 TANK, RESERVOIR . . . . . . . . . 1
17 360-25854-00-00 DIAPHRAGM, RESERVOIR ... 1
18 2GU-25855-00-00 BUSH, DIAPHRAGM ........ 1
19 2KF-25852-50-00 CAP, RESERVOIR . . . . . . . . . . 1
21 31A-14477-00-00 PLATE . . . . . . . . . . . . . . . . . . . 1
22 1WG-25895-00-00 HOSE, RESERVOIR . . . . . . . . . 1
23 90467-14057-00 CLIP .................... 2
24 (3BF-25872-50-00) HOSE, BRAKE 1 ........... 1
25 90401-10096-00 BOLT, UNION ............. 2
26 90201-10118-00 WASHER, PLATE . . . . . . . . . . . 4
FZR400U
E5

FAIRING-COWLING
Ref. Part
1 2AX-28381-00-00 WINDSHIELD . . . . . . . . . . . . . . 1
2 90150-05020-00 SCREW, ROUND HEAD . . . . . . 6
3 95706-05500-00 NUT, FLANGE . . . . . . . . . . . . . 6
4 46X-28376-01-00 TRIM . . . . . . . . . . . . . . . . . . . . 1
5 3FH-2835G-00-GE BODY, FRONT UPPER 1 . . . . . 1 SILKY WHITE
6 3FH-28356-00-00 STAY 1 .................. 1
7 1WG-28365-00-00 COVER .................. 1
8 90480-14229-00 GROMMET . . . . . . . . . . . . . . . . 4
9 90179-06500-00 NUT . . . . . . . . . . . . . . . . . . . . . 4
10 95816-08045-00 BOLT, FLANGE . . . . . . . . . . . . 2
11 1WG-Y283U-00-GE PANEL ASSEMBLY 1 . . . . . . . . 1 SILKY WHITE
12 90480-13398-00 . GROMMET . . . . . . . . . . . . . . . 2
13 90387-067K6-00 . COLLAR ................ 2
14 1WG-28328-00-00 . EMBLEM . . . . . . . . . . . . . . . . 1
15 1WG-Y283V-00-GE PANEL ASSEMBLY 2 . . . . . . . . 1 SILKY WHITE
16 90480-13398-00 . GROMMET . . . . . . . . . . . . . . . 2
17 90387-067K6-00 . COLLAR ................ 2
18 1WG-28338-00-00 . EMBLEM . . . . . . . . . . . . . . . . 1
19 91316-06020-00 BOLT, SOCKET HEAD . . . . . . . 2
20 90201-062A8-00 WASHER, PLATE . . . . . . . . . . . 2
21 90110-06078-00 BOLT, HEXAGON SOCKET . . . 1
22 90110-05079-00 BOLT, hexagon socket head . . 4
23 90202-05180-00 WASHER, PLATE . . . . . . . . . . . 4
24 90183-05024-00 NUT, SPRING . . . . . . . . . . . . . . 4
25 1WG-2831U-00-00 STAY, SIDE 1 . . . . . . . . . . . . . . 2
26 91026-06012-00 BOLT, FLANGE (1VJ) ....... 2
27 90387-07391-00 COLLAR ................. 1
HEAD . . . . . . . . . . . . . . . . . . . . 1
FZR400U
E6

FAIRING-COWLING
Ref. Part
29 1KT-26280-00-00 MIRROR ASSEMBLY

(WHITE)ASSEMBLY (L) . . . . . . 1 UR WHITE
30 1KT-26290-00-00 MIRROR ASSEMBLY
(WHITE)ASSEMBLY (R) . . . . . . 1 UR WHITE
31 1KT-28371-00-00 DAMPER . . . . . . . . . . . . . . . . . 2
32 1KT-28372-00-00 DAMPER . . . . . . . . . . . . . . . . . 2
33 92906-06100-00 WASHER, SPRING . . . . . . . . . . 4
34 95306-06800-00 NUT . . . . . . . . . . . . . . . . . . . . . 4
35 3FH-2836E-00-00 BRACKET 2 . . . . . . . . . . . . . . . 1
36 1WG-Y283J-30-0X BODY, FRONT LOWER 1 . . . . . 1
37 1WG-28393-00-00 . GRAPHIC 3 . . . . . . . . . . . . . . 1
38 1WG-28398-00-00 . GRAPHIC 5 . . . . . . . . . . . . . . 1
39 1WG-2839A-00-00 . GRAPHIC 7 . . . . . . . . . . . . . . 1
40 1WG-2839F-00-00 . GRAPHIC 9 . . . . . . . . . . . . . . 1
41 99234-00070-00 . EMBLEM, YAMAHA . . . . . . . . 1 FOR W
42 90480-13398-00 . GROMMET . . . . . . . . . . . . . . . 2
43 90387-067K6-00 . COLLAR ................ 2
44 1WG-28390-00-00 GRPHC SET, COWLING . . . . . . 1
45 1WG-Y283K-30-0X BODY, FRONT LOWER 2 . . . . . 1
46 1WG-28394-00-00 . GRAPHIC 4 . . . . . . . . . . . . . . 1
47 1WG-28399-00-00 . GRAPHIC 6 . . . . . . . . . . . . . . 1
48 1WG-2839E-00-00 . GRAPHIC 8 . . . . . . . . . . . . . . 1
49 1WG-2839G-00-00 . GRAPHIC 0 . . . . . . . . . . . . . . 1
50 99234-00070-00 . EMBLEM, YAMAHA . . . . . . . . 1 FOR W
51 90480-13398-00 . GROMMET . . . . . . . . . . . . . . . 2
52 90387-067K6-00 . COLLAR ................ 2
53 90110-06078-00 BOLT, HEXAGON SOCKET . . . 4
54 90110-05079-00 BOLT, hexagon socket head . . 8
55 90202-05180-00 WASHER, PLATE . . . . . . . . . . . 8
FZR400U
E7

FAIRING-COWLING
Ref. Part
56 90183-05024-00 NUT, SPRING . . . . . . . . . . . . . . 6

57 90179-05523-00 NUT . . . . . . . . . . . . . . . . . . . . . 2
58 1WG-2836A-00-00 BRACKET 1 . . . . . . . . . . . . . . . 2
59 1WG-2836E-00-00 BRACKET 2 . . . . . . . . . . . . . . . 1
60 91026-06010-00 BOLT . . . . . . . . . . . . . . . . . . . . 4
61 8K4-77374-00-00 DAMPER 2 . . . . . . . . . . . . . . . . 2
62 99231-00025-00 EMBLEM . . . . . . . . . . . . . . . . . 1 FOR FWR
FZR400U
E8

METER
Ref. Part
1 3FH-83570-00-00 SPEEDOMETER ASSEMBLY . . 1

2 3FH-83540-00-00 TACHOMETER ASSEMBLY . . . 1
3 1WG-83590-00-00 WATER TEMP
METERASSEMBLY ......... 1
4 47X-83530-00-00 PILOT LIGHT ASSEMBLY . . . . 1
5 1WG-83513-00-00 DAMPER . . . . . . . . . . . . . . . . . 1
6 1WG-83519-00-00 BRACKET, METER ......... 1
7 584-83523-00-00 DAMPER . . . . . . . . . . . . . . . . . 6
8 90201-052E2-00 WASHER, PLATE . . . . . . . . . . . 6
9 95306-05600-00 NUT . . . . . . . . . . . . . . . . . . . . . 6
10 98501-03012-00 SCREW, PAN HEAD ........ 3
11 92990-03100-00 WASHER, SPRING
(92901-03100) . . . . . . . . . . . . . 3
12 97780-30120-00 SCREW, PANHEAD TAP . . . . . 2
14 3FH-83520-00-00 SOCKET CORD ASSEMBLY .. 1
15 4G1-84744-00-00 BULB, MTR.12V3.4W . . . . . . . . 4
16 1WG-83588-00-00 NUT, PILOT LIGHT . . . . . . . . . . 1
17 3GM-83517-00-00 BULB (12V-1.7W) . . . . . . . . . . . 5
18 90480-14229-00 GROMMET . . . . . . . . . . . . . . . . 3
19 90201-06059-00 WASHER, PLATE . . . . . . . . . . . 3
20 95316-06600-00 NUT . . . . . . . . . . . . . . . . . . . . . 3
21 46X-83550-00-00 SPEEDOMETER
CABLEASSEMBLY ......... 1
FZR400U
E9

HEADLIGHT
Ref. Part
1 3BF-84310-00-00 HEADLIGHT UNIT

ASSEMBLYASSY . . . . . . . . . . . 1
2 2AX-84330-00-00 . BODY ASSEMBLY. ........ 1
3 93210-06632-00 . O-RING ................. 2
4 3BF-84320-00-00 . LENS ASSEMBLY. . . . . . . . . . 1
5 3BF-8432A-00-00 . LENS ASSEMBLY. . . . . . . . . . 1
6 3MA-8430M-00-00 . GEAR UNIT ASSEMBLY .... 2
7 97706-40616-00 . SCREW, TAPPING . . . . . . . . . 4
8 2AX-84331-00-00 . SCREW, RIM ADJUSTING . . . 2
9 2F9-84397-01-00 . COVER, SOCKET . . . . . . . . . . 2
10 51L-8431U-00-00 . HOLDER ................ 2
11 51L-84332-00-00 . SPRING, SCREW . . . . . . . . . . 4
12 3BF-84396-00-00 . COVER ................. 1
13 2F9-84375-00-00 . SETTING PLATE, BULB . . . . . 2
14 1ML-84314-00-XX BULB (12V-35/35W)
(1FM-84314-H0-00) . . . . . . . . . . 2 HALOGEN
15 46X-84397-01-00 COVER, SOCKET . . . . . . . . . . . 2
FZR400U
E10

TAILLIGHT
Ref. Part
1 1UJ-84710-A0-00 TAILLIGHT UNIT ASSEMBLY . . 1

2 1FN-84721-E0-00 . LENS, TAILLIGHT ......... 1
3 47X-84723-00-00 . GASKET, TAIL LENS . . . . . . . 1
4 1A2-84718-40-00 . GROMMET . . . . . . . . . . . . . . . 1
5 256-84714-61-00 . BULB (12V-27/8W) . . . . . . . . . 1
6 1UJ-84735-A0-00 . CORD ASSEMBLY . . . . . . . . . 1
7 90480-18276-00 GROMMET . . . . . . . . . . . . . . . . 2
8 90201-063J2-00 WASHER, PLATE . . . . . . . . . . . 2
9 90387-07037-00 COLLAR ................. 2
10 95380-06600-00 NUT . . . . . . . . . . . . . . . . . . . . . 2
11 2AX-84745-00-00 LICENSE LIGHT UNIT ASS’’Y
(4H3-84745-60-00) . . . . . . . . . . 1
12 2AX-84749-00-00 . BODY, LICENSE LIGHT . . . . . 1
13 2AX-84741-00-00 . BASE, LICENSE LIGHT . . . . . 1
14 3F9-84744-00-XX . BULB, METER 12V3.8W . . . . . 2
15 3F9-84742-00-00 SEAT, BASE .............. 1
16 3F9-84757-00-00 COLLAR, LCNSE BRKT . . . . . . 2
17 3F9-84553-00-00 DAMPER . . . . . . . . . . . . . . . . . 2
18 90201-05031-00 WASHER, PLATE . . . . . . . . . . . 2
19 95701-05500-00 NUT, FLANGE . . . . . . . . . . . . . 2
20 1KH-84751-00-90 BRACKET, LICENSE . . . . . . . . 1
21 90201-06067-00 WASHER, PLATE . . . . . . . . . . . 2
22 92906-06100-00 WASHER, SPRING . . . . . . . . . . 2
23 95316-06700-00 NUT 54G . . . . . . . . . . . . . . . . . 2
24 3Y6-85130-02-00 REAR REFLECTOR ASSEMBLY 2
25 1FK-85130-00-00 REAR REFLECTOR ASSEMBLY 1
26 95701-05500-00 NUT, FLANGE . . . . . . . . . . . . . 4
FZR400U
E11

TURNSIGNAL
Ref. Part
1 1UF-83310-00-00 FRONT FLASHER LIGHT

ASSEMBLY 1 . . . . . . . . . . . . . . 1
2 51L-83332-01-00 . LENS, FLASHER . . . . . . . . . . 1
3 256-84714-61-00 . BULB (12V-27/8W) . . . . . . . . . 1
4 97706-40620-00 . SCREW, TAPPING . . . . . . . . . 1
5 1UF-83320-00-00 FRONT FLASHER LIGHT
ASSEMBLY 2 . . . . . . . . . . . . . . 1
6 51L-83342-01-00 . LENS, FLASHER 2 . . . . . . . . . 1
7 256-84714-61-00 . BULB (12V-27/8W) . . . . . . . . . 1
8 97706-40620-00 . SCREW, TAPPING . . . . . . . . . 1
9 95701-12500-00 NUT, FLANGE . . . . . . . . . . . . . 2
10 46X-83365-00-00 CAP . . . . . . . . . . . . . . . . . . . . . 2
11 2MA-28365-01-00 COVER .................. 2 CLEAN WHITE
12 90183-04045-00 NUT, SPRING . . . . . . . . . . . . . . 4
13 90480-35526-00 GROMMET . . . . . . . . . . . . . . . . 2
14 1UF-83330-00-00 REAR FLASHER LIGHT
ASSEMBLY 1 . . . . . . . . . . . . . . 1
15 51L-83342-01-00 . LENS, FLASHER 2 . . . . . . . . . 1
16 256-83311-70-XX . BULB, TS 12V27W . . . . . . . . . 1
17 97706-40620-00 . SCREW, TAPPING . . . . . . . . . 1
18 1UF-83340-00-00 FLASHER LIGHT ASSEMBLY 2 1
19 51L-83332-01-00 . LENS, FLASHER . . . . . . . . . . 1
20 256-83311-70-XX . BULB, TS 12V27W . . . . . . . . . 1
21 97706-40620-00 . SCREW, TAPPING . . . . . . . . . 1
22 95701-12500-00 NUT, FLANGE . . . . . . . . . . . . . 2
23 46X-83365-00-00 CAP . . . . . . . . . . . . . . . . . . . . . 2
FZR400U
E12

ELECTRICAL 1
Ref. Part
1 1WG-82310-10-00 IGNITION COIL ASSEMBLY . . . 1 4

2 1WG-82320-10-00 IGNITION COIL ASSEMBLY . . . 1 3
3 97011-06025-00 BOLT (97001-06025) ........ 4
4 92995-06100-00 WASHER, SPRING . . . . . . . . . . 4
5 1WG-82370-00-00 PLUG CAP ASSEMBLY . . . . . . 4
6 3BF-82305-00-00 IGNITOR UNIT ASSEMBLY 1 . . 1
7 97702-60120-00 SCREW, TAPPING
(97702-60520-00) . . . . . . . . . . . 2
8 36Y-81940-00-00 STARTER RELAY ASSEMBLY . 1
9 95701-06500-00 NUT, FLANGE . . . . . . . . . . . . . 2
10 4U8-81980-M0-00 DIODE ASSEMBLY ......... 1 FOR SIDE STAND
SAFETY DEVISE
11 BTG-GM12A-Z3-A2 BATTERY ASSEMBLY
(GM12AZ-3A-2)
(2GV-82110-G0-00) . . . . . . . . . . 1
12 1WG-82115-00-00 WIRE, PLUS LEAD . . . . . . . . . . 1
13 3WP-82116-00-00 WIRE, MINUS LEAD
(46X-82116-00) . . . . . . . . . . . . . 1
14 90445-080F4-00 HOSE . . . . . . . . . . . . . . . . . . . . 1
15 1AE-82150-00-00 FUSE HOLDER ASSEMBLY . . . 1
16 1AE-82151-00-00 . FUSE (30A-BL) ........... 2
17 1KT-82530-02-00 STOP SWITCH ASSEMBLY . . . 1
18 3FH-82590-00-00 WIRE HARNESS ASSEMBLY . . 1
19 116-82151-00-00 . FUSE (10A) . . . . . . . . . . . . . . 4
20 4X7-82151-00-00 . FUSE . . . . . . . . . . . . . . . . . . . 2
21 47X-81960-A2-00 RECTIFIER & REGULATOR
ASSEMBLY . . . . . . . . . . . . . . . 1
22 98503-06014-00 SCREW, PAN HEAD
(92502-06016) . . . . . . . . . . . . . 2
23 92995-06100-00 WASHER, SPRING . . . . . . . . . . 2
24 92990-06600-00 WASHER, PLATE . . . . . . . . . . . 2
FZR400U
F1

ELECTRICAL 1
Ref. Part
25 3FH-82501-10-00 MAIN SWCH STRG

LCKSTEERING LOCK ....... 1
26 90149-06228-00 SCREW . . . . . . . . . . . . . . . . . . 2
FZR400U
F2

ELECTRICAL 2
Ref. Part
1 1AE-82540-00-00 NEUTRAL SWITCH ASSEMBLY 1

2 93210-29196-00 O-RING .................. 1
3 98503-06014-00 SCREW, PAN HEAD
(92502-06016) . . . . . . . . . . . . . 2
4 11H-83591-00-00 THERMO UNIT . . . . . . . . . . . . . 1
5 1WG-85720-00-00 OIL LEVEL GAUGE ASSEMBLY 1
6 95026-06016-00 BOLT, FLANGE . . . . . . . . . . . . 2
7 2EL-82560-00-00 THERMO SWITCH ASSEMBLY 1
8 1WG-82541-00-00 WIRE, LEAD .............. 1
9 25G-81950-01-00 RELAY ASSEMBLY . . . . . . . . . 1
10 4U8-81950-02-00 RELAY ASSEMBLY.
(4U8-81950-00) . . . . . . . . . . . . . 1 FOR SIDE STAND
11 3FH-82566-00-00 SWITCH, SIDE STAND . . . . . . . 1
12 90152-05016-00 SCREW, COUNTERSUNK .... 2
13 41R-83350-71-00 FLASHER RELAY ASSEMBLY . 1
14 2KR-83371-00-00 HORN ................... 1
15 97026-06010-00 BOLT (97006-06010-00) . . . . . . 1
16 92906-06100-00 WASHER, SPRING . . . . . . . . . . 1
17 11H-85110-01-00 REFLECTOR ASSEMBLY .... 2
18 95701-05500-00 NUT, FLANGE . . . . . . . . . . . . . 2
FZR400U
F3

HANDLE SWITCH-LEVER
Ref. Part
1 3FH-83973-00-00 SWITCH, HANDLE 3 ........ 1

2 98506-05035-00 . SCREW, PAN HEAD ....... 2
3 3FH-83975-00-00 SWITCH, HANDLE 2 ........ 1
4 98506-05040-00 . SCREW, PAN HEAD ....... 1
5 98506-05045-00 . SCREW, PAN HEAD ....... 1
6 29L-82911-01-00 HOLDER, LEVER 1 ......... 1
7 29L-83912-01-00 LEVER L . . . . . . . . . . . . . . . . . 1
8 31A-83913-00-00 COLLAR, LEVER 1 ......... 1
9 31A-82917-00-00 SWITCH . . . . . . . . . . . . . . . . . . 1
10 31A-83945-00-00 BOLT, LEVER ............. 1
11 98702-03008-00 SCREW, FLAT HEAD . . . . . . . . 1
12 95616-06100-00 NUT, U . . . . . . . . . . . . . . . . . . . 1
13 97011-06025-00 BOLT (97001-06025) ........ 1
14 92906-06100-00 WASHER, SPRING . . . . . . . . . . 1
15 90465-13169-00 CALMP .................. 3
16 36Y-83922-00-00 LEVER R . . . . . . . . . . . . . . . . . 1
HEAD . . . . . . . . . . . . . . . . . . . . 1
18 95616-06100-00 NUT, U . . . . . . . . . . . . . . . . . . . 1
19 36Y-83913-01-00 COLLAR, LEVER 1 ......... 1
22 90170-06010-00 NUT . . . . . . . . . . . . . . . . . . . . . 1
23 J45-82503-01-00 SWITCH, ALARM . . . . . . . . . . . 1
24 98506-04018-00 SCREW, PAN HEAD ........ 1
25 92906-04600-00 WASHER, PLATE . . . . . . . . . . . 1
26 90338-09012-00 PLUG . . . . . . . . . . . . . . . . . . . . 1
FZR400U
F4

FZR400U
K1

FZR400U
K2

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Yamaha

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MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l

IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . ....... l-2

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-4

LUBRICATION DIAGRAM. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

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MAINTENANCE INTERVALS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-l

COWLING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .3-4

CHASSIS ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

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ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-l

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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ENGINE ASSEMBLY AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .4-49

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WATER PUMP AND THERMOSTATIC VALVE. . . . . . . . . . . . . . . . . . . . . . . 5-6

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

STEERING HEAD AND HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . . . . 7-47

DRIVE CHAIN AND SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

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FZR400U/SUC CIRCUIT DIAGRAM ............................ 8-1

ELECTRICAL COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CHECKING OF SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

CHECKING OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-l 1

ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69

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METER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89

STARTING FAILURE/HARD STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

POOR MEDIUM AND HIGH SPEED PERFORMANCE.. . . . . . . . . . . . . . . . . 9-4

FAULTY GEAR SHIFTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

OVERHEATING OR OVER-COOLING.. . . . . . . . . . I.. . . . . . . . . . . . . . . . . 9-6

FAULTY BRAKE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _. . . . 9-7

FRONT FORK OIL LEAKAGE/MALFUNCTION.. . . . . . . . . . . . . . . . . . . . . 9-7

INSTABLE HANDLING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

FAULTY SIGNALS AND LIGHTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

FAULTY EXUP (For California only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-l 0

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PERIODIC INSPECTIONS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 6

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Starting serial number:

ENGINE SERIAL NUMBER

Starting serial number:

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.: ‘.I. . . , ‘,‘;:.‘;. . ;. .;: *

Brake Fluid Type DOT#4or DOT#3

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