07 r6 service manual

, Ltd. is expressly prohibited. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) COOL CARB 7 Chassis. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts. EB102010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and ap- pearance, but inferior in quality. Therefore, when using a dynamometer always use a fan to cool the muffler.Dry with an air blower.To reduce the water temperature change, the coolant starts flowing through the notch depending on its area at a section. High tension cord was cut an end to use and ignition energy loss has become lower. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Rod holder 90890-01434 This tool is used to support the damper ad- justing rod. Rod puller Rod puller 90890-01437 Rod puller attachment. Timing light 90890-03141 This tool is used to check the ignition timing. Oil pressure Oil pressure gauge gauge Adapter 90890-03153 Adapter These tools are used to measure engine oil 90890-03139 pressure. Ignition checker 90890-06754 This tool is used to check the ignition system components. Yamaha bond No.

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I’ve always had a passion for sportbikes and over the years became a gym rat. Join me through my journey of Fitness Vlogging, Motovlogging, and being a Self-proclaimed Iron Addict. Riding a 2004 Yamaha YZF-R6. This is the most complete Service Repair Manual for the 2006-2007 Yamaha YZF-R6 ever compiledThis DOWNLOAD contains.This is the most complete Service Repair Manual for the 2006-2007 Yamaha YZF-R6 ever compiledThis DOWNLOAD contains of high quality diagrams and instructions on how to serviceThis is a must for the. Do-It-Yourselfer! You will not be dissatisfied. Downloadable: YES. File Format: PDF. Language: English. Requirements: Adobe PDF Reader. Models Covers:This Service Repair Manual Covers. General Information. Specifications. Periodic checks and adjustments. Chassis. Engine. Cooling system. Fuel system. Electrical system. Troubleshooting. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. For help you can check writing expert. Check out, please ? www.HelpWriting.net ? I think they are the bestThis Service Manual haseasy-to-read text sections with top quality diagrams and instructions.Trust 2006-2007 Yamaha YZF-R6 Service Repair Manual will giveyou everything you need to do the job. Save time and money by doingit yourself, with the confidence only a 2006-2007 Yamaha YZF-R6Service Repair Manual can provide.Models Covers:2006 Yamaha YZFR6V(C)2006 Yamaha YZFR6V2006 Yamaha YZFR6SPVC2006 Yamaha YZFR6SPV2007 Yamaha YZFR600WC2007 Yamaha YZFR600W2007 Yamaha YZF-R600WC Allpages are printable. Now customize the name of a clipboard to store your clips. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co.

S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. S air filter case S heat protector plate Refer to “AIR FILTER CASE AND IGNITION COILS”. Replace the spark plug. S insulator 2 Abnormal color. Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: S spark plug (with a spark plug cleaner or wire brush) 7. Carbon deposits ! Eliminate. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. API standard SE or higher grade (Non-Friction modified) ACEA standard G4 or G5 CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could. Oil filter wrench 90890-01426 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 14. Install: S bottom cowling Refer to “COWLINGS”. EB303090 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark. Add the recommended engine oil to the proper level. The following data should be used only as a reference when measuring the engine oil pressure. S air filter case cover 1 S air filter element 2. Clean: S air filter element Use solvent to clean the air filter element. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level. S reservoir hose clamps 1 2.

1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-11. This chart specifies tightening torques for standard Use this table to convert METRIC unit data fasteners with a standard ISO thread pitch. Clutch springs Bolt Drive sprocket Use a lock. Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Front mounting bolts. Locate the end of band to forward. H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Q 1: Speed sensor connector V Route the fan motor lead under the throttle cable 2: AC magneto connector and then, fasten the fan motor lead and throttle 3: Sidestand switch connector. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. NOTE: S The air filter element needs more frequent service if you are riding in unusually wet or dusty areas. Bolt Bolts Fuel sender coupler. Rear cowling Bottom cowling (left) Bottom cowling (right) Front cowling inner panel (left) Front cowling inner panel (right) Side cowling inner panel (left) Side cowling inner panel (right) INSTALLATION 1. Install: S side cowlings S rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Front cowling inner panel (left) Refer to “COWLINGS”. INSTALLATION 1. Install: S heat protector plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the rubber baffle and push the. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature.

S Do not use a high-rate battery charger Ambient temperature. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16 X 17 V. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- meter to the battery and start charging. Clean with a wire brush. Headlight beams is low- Direction ered. Reserve tank Refer to “CHANGING THE COOLANT” Locknut Shift rod Shift arm Drive sprocket cover Lock washer. Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3 Coolant Drain. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE AND IGNITION COILS” in chapter 3. Carburetor assembly and joints Refer to “CARBURETORS”. Startor coil assembly coupler Pickup coil coupler Engine earth Clutch wire and holder Crankcase breather hose Separator For connecting reverse the discomecting procedure. Carburetor assembly Refer to “CARBURETORS” in chapter 6. Radiator assembly Refer to “RADIATOR”. Pickup coil rotor cover Refer to “PICKUP COIL AND PICK UP COIL COVER”. Timing chain guide (intake side) For installation reverse the removal procedure. Re- place the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification. Replace the cam- shaft. Camshaft lobe dimensions limit Intake camshaft a 33.0 mm b 25.09 mm Exhaust camshaft. S Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap clearance with the Plastigauge. Camshaft cap bolt 10 Nm (1.0 mSkg) d. Replace the camshaft sprockets and the timing chain as a set.S camshaft sprocket timing mark c Make sure that the camshaft sprocket timing mark is aligned with the cylinder head edge Out of alignment ! Adjust. Intake and exhaust camshafts Refer to “CAMSHAFTS”. Water hose Disconnect Temp senser lead Disconnect Front mounting bolt Refer to “ENGINE”.

Remove: S coolant reservoir bolts 2 S coolant reservoir cap 3 NOTE: When draining the coolant from the coolant res- ervoir, be sure to tilt the reservoir so that coolant cannot flow through the coolant reservoir breather hose 4. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. S Use only distilled water. However, soft wa- ter may be used if distilled water is not available. Direction Brake pedal is raised. Direction Brake pedal is lowered. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a. Add the recommended brake fluid to the proper level. Replace the brake pads as a set. Tighten the clamp bolt. If the drive chain is not maintained prop- erly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 9 Nm (0.9 mSkg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. Steering head tension 200 X 500 g e. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over. Rebound damping is Direction decreased (suspension is. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. No guarantee con-. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. Time (minutes) Check the open-circuit CAUTION: voltage. S Never remove the MF battery sealing caps.

S Lubricate the bolt threads and nut seats with molybdenum disulfide grease. S Make sure that the “Y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up. Crankcase lower Separate. Refer to “CRANKCASE”. Connecting rods and pistons Refer to “CONNECTING RODS AND PISTONS”.If the clearance is out of specification, select replacement crankshaft journal bearings. 2. Select: S crankshaft journal bearings (J NOTE: S The numbers stamped into the crankshaft web and the numbers stamped into the lower. S Be sure to install each crankshaft journal up- per bearing in its original place. Crankcase lower Separate. Refer to “CRANKCASE”. Shift shaft and stopper lever Refer to “SHIFT SHAFT”. Drive axle assembly Circlip Oil seal. Shift fork “R” Refer to “REMOVING THE Shift drum assembly TRANSMISSION”. Shift fork “C” Main axle assembly For installation, reverse the removal procedure. Replace the shift fork(-s) and shift fork guide bar as a set. Replace the shift drum assembly. Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement.Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Oil cooler outlet hose Thermo switch coupler Disconnect. Radiator fan motor coupler Disconnect. Radiator Radiator fan For installation reverse the removal procedure. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2. Repair or replace any faulty part. 3. Radiator assembly Refer to “RADIATOR”. Exaust pipe assembly Refer to “ENGINE” in chapter 4. Engine oil Drain. Rider seat and fuel tank Refer to “SEAT” and “FUEL TANK” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Air filter case Refer to “AIRFILTER CASE AND IGNITION COILS”. Repair or replace any faulty part. 5. Measure: S radiator cap opening pressure Below the specified pressure. Replace the radiator cap. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3.

Water pump inlet hose Water pump outlet hose Water pump hose Clutch wire and holder Water pump. Oil seal Bearing Circlip. S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer 90890-04078 4 Middle driven shaft bearing. Repeat steps (3) and (4). CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Max. impeller shaft tilt 0.15 mm 1 Straightedge 2 Impeller. Rider seat and fuel tank Refer to “Seats” and “FUEL TANK” in chapter 3. Air filter case and heat protector plate Refer to “AIR FILTER CASE AND IGNITION COILS”. Starter plunger link Refer to “ASSEMBLING THE Connecting bolt CARBURETORS” Connecting bolt Hose joint Spring Refer to “ASSEMBLING THE CARBURETORS” Fuel feed pipe Fuel feed pipe Pipe Throttle stop screw Throttle position sensor. NOTE: The following procedure applies to all of the carburetors. Starter plunger Air funnel Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit Piston valve Refer to “ASSEMBLING THE Pilot screw. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleumbased sol- vent. Tester positive probe.NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode. Refer to “FUEL TANK” in chapter 3. b. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor. c. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel cock to “ON”. Oil seals (left and right) Wheel bearings (left and right) Spacer For assembly, reverse the disassembly procedure. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Re- place the wheel bearings. Correct the brake disc deflection or replace the brake disc.

After all of the bolts and nuts are fully loosened, remove them. NOTE: To ensure an even surface, rotate the cylinder head several times.Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Valve spring compressor 90890-04019 Attachment 90890-04114 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4. Replace the valve. Valve margin thickness 0.6 mm X 0.8 mm: 0.5mm 6. Measure: S valve stem runout Out of specification. Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. Replace the valve spring.S Each valve lifter and valve pad must be rein- stalled in its original position. After all of the bolts are fully loosened, remove them. Sheave holder 90890-01701 3. Apply: S sealant (onto the pickup coil lead grommet) Yamaha bond No.1215 90890-85505 4. Install: S pickup coil cover S clutch cable holder NOTE: S When installing the pickup coil cover, align the timing chain guide (intake side) pin 1 of the with the hole 2 in the pickup coil cover. Generator rotor Starter one-way assy Idler gear shaft Idler hear Starter clutch gear For installation reverse the removal proceduer. After all of the bolts are fully loosened, remove them. 2. Sheave holder 90890-01701 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505 4. Install: S stator coil 5. Install: S generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. Coolant reserver Drain. Refer to “CHNGING THE COOLANT” in chapter 3. Drive sprocket cover, sift rod and sift Refer to “ENGINE”. Shift shaft spring stopper For installation reverse the removal procedure. 4-41. Replace the stopper lever.

Bottom cowing and right side cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain. Clutch cover gasket Dowel pin For installation reverse the removal procedure. 4-44. Pull lever spring Oil seal Bearing For assembly, reverse the disassembly procedure. 4-45. Compression spling Pressure plate Pull rod Refer to “INSTALLING THE CLUTCH”.After all of the bolts are fully loosened, remove them. S Pressure plate S Fricttion and clutch plates 2. Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge Out of specification. Replace the clutch plates as a set. Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause er- ratic clutch operation.Engine oil Drain. Dowel pin Oil strainer Refer to “INSTALLING THE OIL. Repair or replace the defective part(-s). Replace the defective part(-s). Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Starter clutch and generator Refer to “STARTER CLUTCH AND GENERATOR”. Shift shaft Refer to “SHIFT SHAFT”. Dowel pin For installation, reverse the removal procedure. 4-60. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration). Blow out with compressed air. S Install a washer on bolts 1 X S Install a gasket on bolt S Not lubricate seal botts 18 12 S Tighten the bolts in the tightening sequence cast on the crankcase. Refer to “CRANKCASE”.Oil ring For installation, reverse the removal procedure. 4-67. Replace the crank- cases, and the piston and piston rings as a set. Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.15 X 0.25 mm. Replace the piston pin.NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed.

NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 7-10. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Over the specified limits ! Replace. Max. radial wheel runout 1.0 mm Max. lateral wheel runout 0.5 mm EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. The following procedure applies to both of the front brake calipers. Brake caliper bolts Brake pads Refer to “REPLACING THE REAR Brake pad shims. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Replace the brake pads as a set. Add the recommended brake fluid to the proper level. Replace the brake pads as a set. Brake pad wear limit 0.8 mm 4. Install: S brake pad shims (onto the brake pads) S brake pads NOTE: Always install new brake pads, brake pad. Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. Brake master cylinder Front brake switch For installation, reverse the removal procedure. S Align the end of the brake master cylinder holder with the punch mark a in the right han- dlebar. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a. Add the recommended brake fluid to the proper level. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system.

The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad. Brake fluid Drain. Union bolt Refer to “INSTALLING THE REAR Copper washer BRAKE CALIPERS”. Brake pad Brake caliper piston Refer to “REMOVING THE REAR Brake caliper piston seal BRAKE CALIPERS”. NOTE: Before removing either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Front brake calipers The following procedure applies to both of the front fork legs. The following procedure applies to both of the front fork legs.Outer tube bushing Inner tube Oil lock piece For assembly, reverse the disassembly procedure. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. WARNING The fork spring is compressed. f. Be careful not to damage the inner tube. 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and suspension oil 01 or equivalent 7-48. Damper rod holder 90890-01425 4. Install: S outer tube bushing 1 S washer 2 S oil seal 3 S oil seal clip 4. Other oils may have an adverse effect on front fork performance. NOTE: Be careful not to stroke the inner tube over 100 mm as this will cause air to enter.

If the inner tube is stroked more than 100 mm, repeat steps (12) and (13). Rod puller 90890-01437 Adapter 90890-01436 d. Install the fork spring, washers and spacer. e. Press down on the spacer with the fork spring compressor 8. f. EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Right handlebar switch Refer tp “INSTALLING THE Brake master cylinder holder HANDLEBARS”. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S grip end S handlebar grip S left handlebar switch S clutch lever holder NOTE: Blow compressed air between the left handle-. S First, tighten the upper bolt, then the lower bolt. NOTE: S Align the mating surfaces of the brake master cylinder holder with the punch mark a in the right handlebar. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S front fork legs S steering stem nut S upper bracket S ring nuts 1 (with the special tool 2 ) CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearing balls and bearing races as a set. NOTE: Temporarily tighten the upper and lower bracket pinch bolts, and handlebar pinch bolts. 5. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Drive chain Dust cover Oil seal Bush Shim Drive chain guide Bush Left bearing Right bearing. EC573000 REMOVING THE SWINGARM 1. Remove: S Bolt (connecting rod) 1 S Connecting rod 2 NOTE: Remove the bolt while holding the swingarm. WARNING Securely support the motorcycle so that there is no danger of it falling over.

NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Bends ! Replace. WARNING Do not attempt to straighten a bent pivot shaft. 5. Wash: S pivot shaft S pivot shaft adjust bolt S dust covers S spacer S bearings. Replace the drive chain. Max. ten-link drive chain section 149 mm NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. Neutral indicator light “ ” This indicator comes on when the transmis- sion is in neutral. High beam indicator light “. Push the “SELECT” button to change be- tween the fuel odometer, trip odometer and odometer modes in the following order: “TRIP F”. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1. Refer to “CHECKING SWITCH CONTINUITY”. Improperly connected. Properly connect. Incorrect continuity reading. Replace the switch. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING THE spark or intermittent spark). BATTERY” in chapter 3. Check: Min. open-circuit voltage 1. S Remove the relay unit from the wire harness.The starter motor fails to turn. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2. S Disconnect the relay from the coupler.S Check the engine stop switch for continuity. S Is the engine stop switch OK.Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK. Replace the sidestand switch. EB803405 12. Clutch switch S Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”.

Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Carburetors Refer to “CARBURETORS”. O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O-ring Brush holder set O-ring. Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification. Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: S mica undercut a Out of specification. Scrape the mica to the proper measurement with a hacksaw blade. Replace the brushes as a set. Min. brush length 3.5 mm 6. Measure: S brush spring force Out of specification. Replace the brush springs as a set. Brush spring force 7.16 X 9.52 N (7.16 X 9.52 gf) 7. The battery is not being charged.Refer to “CIRCUIT DIAGRAM”. S Is the charging system’s wiring properly con- nected and without defects. The charging circuit is OK. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING THE light, high beam indicator light, taillight, BATTERY” in chapter 3. auxiliary light or meter light.Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? 1. This circuit is OK. S Set the main switch to “ON”.S Set the light switch to “ ” or “ ”. S Is the voltage within specification. This circuit is OK. S Any of the following fail to light: turn sig- Refer to “CHECKING THE BATTERY” in nal light, brake light or an indicator light. S The horn fails to sound. chapter 3. S Disconnect the black connector at the horn terminal. 1. Horn switch S Connect a jumper lead to the horn terminal S Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”. S Is the turn signal switch OK. Replace the left han- dlebar switch. S Connect the pocket tester (DC 20 V) to the S Measure the voltage (12 V) of chocolate meter assembly coupler (wire harness side) dark green at the turn signal light connec-. S Disconnect the fuel sender coupler from the S Is the voltage within specification.S Is the speedometer bulb socket OK.