Everything from re-wiring to rebuilding the engine is covered - as well as electrical diagrams, service procedures, fluid capacities, Etc. Oil breather plate bolt: 1st: 1. Refer to the following part numbers. Electro- lyte contains sulfuric acid. This could deform or loosen the cable end due to extreme angles and or pressure.
Internal: Drink large quantities of water or milk. Exhaust component parts sub-assembly 1. Armature coil continuity: Commutator segments 1 Continuity Segment - Laminations 2 No continuity Segment - Armature shaft No continuity Brush holder inspection 1. If the oil filter is also to be replaced, per- form the following procedure. Impro- visations and using improper tools can dam- age the equipment.
Damaged or mis- handled instruments will not measure properly. Antidotes External: Flush with water. Handlebar switch lead Handlebar assembly Reverse the removal steps for installation. Camshaft journal diameter: Intake: 24. Bolt Damper 1 Damper 2 Bolt Engine mount Liner.
It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Fuel pump filter inspection 1. Valve spring free length: Intake valve spring: 38. Depending on operating conditions, the intervals of maintenance should be changed. Minimum compression pressure reference data : 1,150 kPa 11. How- ever, if there are numerous error codes dis- played, be sure to check them with the Yamaha Diagnostic System. Also, it is suggested to apply a thin film of anti- seize compound to the spark plug threads to prevent thread seizure.
Use compressed air to remove dust and dirt during disassembly. Use only the latest edition of this manual. Big end oil clearance: 0. Operate the oil changer to extract the oil. Engine oil level check 1.
Fuel pump module removal 1. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Cooling water hose inspection 1. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. Apply engine oil to the contact surfaces of moving parts during assembly. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
Specific gravity at 20 °C 68 °F : 1. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease Yamaha grease A, Yamaha marine grease H Apply ThreeBond 1104J or ThreeBond 1280B. Lubricate: Crankshaft journal bearings with the recommended lubricant Recommended lubricant: Engine oil 2. Eliminate carbon deposits from the valve with a scraper. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. Reface the valve seat with the valve seat cutter. Thermoswitch exhaust continuity temperature: a 80—86 °C 176—187 °F b 66—80 °C 151—176 °F 1 No continuity È Temperature 2 Continuity É.
Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper commer- cially available. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc. Check that there are no incorrect wiring connections. However, you should follow these precautions to minimize any risk when working with lubricants. Valve clearance cold : Intake valve: 0.
The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. End plate Handlebar Reverse the disassembly steps for assembly. Insert the tube of an oil changer into the oil filler hole. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. After all of the bolts are fully loosened, remove them.
Lap the valve slowly on the valve seat with a valve lapper commercially available as shown. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Throttle lever free play a: 4—7 mm 0. Valve stem diameter a: Intake valve: 3. This is an Instant Download Manual, no waiting for the Mail Man! É Fasten the steering sensor lead, handlebar switch lead, multifunction meter lead, and buzzer lead with plastic tie 2. To change the modes again, press the lock button for a short time, and then start the procedures from the lock mode. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat.