Cool

COOLING SYSTEM

RADIATOR

EAS00454

Order

Job/Part

Q'ty

Remarks

Removing the radiator

Remove the parts in the order listed.

Rider seat

Refer to "SEATS" in chapter 3.

Fuel tank

Refer to "FUEL TANK" in chapter 3.

Air filter case

Refer to "AIR FILTER CASE" in chapter 3.

Side cowlings and bottom cowling

Refer to "COWLINGS" in chapter 3.

Refer to "CHANGING THE COOLANT" in chapter 3.

1

Coolant reservoir hose

1

2

Throttle body hose

2

3

Radiator outlet hose

1

4

Coolant pipe

1

5

Radiator inlet hose

1

6

Oil cooler outlet hose

1

7

Radiator

1

8

Radiator fan

1

Order

Job/Part

Q'ty

Remarks

9

Radiator cap

1

For installation, reverse the removal procedure.

EAS00455

CHECKING THE RADIATOR

1. Check: • radiator fins Obstruction ^ Clean.

Apply compressed air to the rear of the radiator.

Damage ^ Repair or replace. NOTE:

Straighten any flattened fins with a thin, flat-head screwdriver.

• radiator hoses

• radiator pipes Cracks/damage

Replace.

3. Measure: • radiator cap opening pressure Below the specified pressure ^ Replace the radiator cap.

Radiator cap opening pressure 110 ~ 140 kPa

(1.1 ~ 1.4 kg/cm2, 1.1 ~ 1.4 bar, 16.0 ~ 20.3 psi)

a. Install the radiator cap tester ® and radiator cap tester adapter (2 to the radiator cap

90890-01325, YU-24460-01

Radiator cap tester adapter 90890-01352, YU-33984

b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

4. Check: • radiator fan Damage ^ Replace. Malfunction ^ Check and repair. Refer to "COOLING SYSTEM" in chapter 8.

INSTALLING THE RADIATOR

• cooling system

(with the specified amount of the recommended coolant)

Refer to "CHANGING THE COOLANT" in chapter 3.

• cooling system

Leaks ^ Repair or replace any faulty part.

3. Measure:

• radiator cap opening pressure

Below the specified pressure ^ Replace the radiator cap.

Refer to "CHECKING THE RADIATOR".

eAS00456

OIL COOLER

EAS00457

63 Nm (6.3 m«kg, 46 ft«lb)

Order

Job/Part

Q'ty

Remarks

Removing the oil cooler

Remove the parts in the order listed.

Radiator assembly

Refer to "RADIATOR".

Engine oil

Refer to "CHANGING THE ENGINE OIL" in chapter 3.

1

Oil cooler outlet hose

1

2

Union bolt

1

3

Washer

1

4

Oil cooler

1

5

Oil cooler inlet hose

1

6

Oil cooler inlet pipe

1

7

Water jacket joint hose

1

8

Water jacket joint

1

9

O-ring

1

10

O-ring

1

11

Water pump hose

2

For installation, reverse the removal procedure.

EAS00458

CHECKING THE OIL COOLER

Cracks/damage ^ Replace.

• oil cooler inlet hose

• oil cooler outlet hose Cracks/damage/wear ^ Replace.

EAS00459

INSTALLING THE OIL COOLER

• mating surfaces of the oil cooler and the crankcase

(with a cloth dampened with lacquer thinner)

2. Install:

New

\

63 Nm (6.3 m^kg, 46 fMb)

• Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil.

• Make sure that the O-ring is positioned properly.

• Align the projection @ on the oil cooler with the slot © in the crankcase.

• cooling system

(with the specified amount of the recommended coolant)

Refer to "CHANGING THE COOLANT" in chapter 3.

(with the specified amount of the recommended engine oil)

Refer to "CHANGING THE ENGINE OIL" in chapter 3.

• cooling system

Leaks ^ Repair or replace any faulty part.

5. Measure:

• radiator cap opening pressure

Below the specified pressure ^ Replace the radiator cap.

Refer to "CHECKING THE RADIATOR".

THERMOSTAT

EAS00461

Order

Job/Part

Q'ty

Remarks

Rider seat

Air filter case

Throttle body assembly

Remove the parts in the order listed.

Refer to "SEATS" chapter 3.

Refer to "AIR FILTER CASE" in chapter 3.

Refer to "THROTTLE BODIES" in chapter

Drain.

Refer to "CHANGING THE COOLANT" in chapter 3.

For installation, reverse the removal procedure.

Radiator inlet hose Thermostat cover Thermostat

1 1 1

CHECKING THE THERMOSTAT

1. Check: • thermostat © Does not open at 71 ~ 85°C (160 ^ Replace.

EAS00462

a. Suspend the thermostat in a container filled with water.

b. Slowly heat the water.

c. Place a thermometer in the water.

d. While stirring the water, observe the thermostat and thermometer's indicated temperature.

® Thermostat (2 Thermometer (3 Water (4 Container [A Fully closed [0 Fully open

If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.

2. Check: • thermostat housing cover Cracks/damage ^ Replace.

INSTALLING THE THERMOSTAT

Install the thermostat with its breather hole @ facing up.

2. Install • thermostat cover

Before installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat of lithium soap based grease.

Fill:

■cooling system

(with the specified amount of the recommended coolant)

Refer to "CHANGING THE COOLANT" in chapter 3.

Check:

■cooling system

Leaks ^ Repair or replace any faulty part. Measure:

■radiator cap opening pressure Below the specified pressure ^ Replace the radiator cap.

Refer to "CHECKING THE RADIATOR".

WATER PUMP

EAS00408

Order

Job/Part

Q'ty

Remarks

Removing the water pump

Remove the parts in the order listed.

Bottom cowling

Refer to "COWLINGS" in chapter 3.

Coolant

Drain.

Refer to "CHANGING THE COOLANT" in

chapter 3.

1

Water pump inlet hose

1

2

Water pump outlet hose

1

3

Water pump hose

1

4

Clutch cable/holder

1/1

5

Water pump

1

NOTE:

It is not necessary to remove the water

pump unless the coolant level is extremely

low or the coolant contains engine oil.

For installation, reverse the removal

procedure.

Order

Job/Part

Q'ty

Remarks

Disassembling the water pump

Disassemble the parts in the order listed.

©

Water pump cover

1

d)

O-ring

1

CD

Impeller shaft

1

®

Circlip

1

0)

Water pump seal

1

©

Oil seal

1

®

Bearing

1

®

Water pump housing

1

For assembly, reverse the disassembly

DISASSEMBLING THE WATER PUMP

1. Remove:

• impeller shaft

Remove the water pump seal from the outside of the water pump housing.

(2 Water pump housing

3. Remove: • oil seal d (with a thin, flat-head screwdriver)

NOTE:

Remove the oil seal from the outside of the water pump housing.

NOTE:

Remove the bearing from inside of the water pump housing.

5. Remove:

(from the impeller, with a thin, flat-head screwdriver)

NOTE:

Do not scratch the impeller shaft.

CHECKING THE WATER PUMP

• water pump seals

Cracks/damage/wear ^ Replace.

Rough movement ^ Replace.

• water pump outlet pipe

• radiator outlet hose Cracks/damage/wear ^ Replace.

EAS00473

EAS00475

ASSEMBLING THE WATER PUMP

1. Install: ^^ • oil seal INllffl ® (into the water pump housing (2)

• Before installing the oil seal, apply tap water or coolant onto its out surface.

• Install the oil seal with a socket that matches its outside diameter.

CAUTION: _

Never lubricate the water pump seal surface with oil or grease.

NOTE:

• Install the water pump seal with the special tools.

• Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket (2 to the water pump housing (3.

Mechanical seal installer

90890-04078, YM-33221 (4) Middle driven shaft bearing driver

90890-04058, YM-04058 (5) Quick Gasket

ACC-11001-05-01 Yamaha bond #1215 90890-85505

3. Install:

• rubber damper holder INSffl (2)

NOTE:

Before installing the rubber damper, apply tap water or coolant onto its outer surface.

4. Measure: • impeller shaft tilt

Out of specification ^ Repeat steps (3) and (4).

CAUTION: _

Make sure the rubber damper and rubber damper holder are flush with the impeller.

Impeller shaft tilt limit 0.15 mm (0.006 in)

® Straightedge (2 Impeller

INSTALLING THE WATER PUMP

1. Install: • water pump assembly

NOTE:

Align the projection ® at the oil pump shaft and water pump shaft groove ©.

2. Install:

NOTE:

• Install the inlet hose with yellow @ mark positioned outside.

• Install the hose clamp with its screw head pointed to the inner side not to contact with the cowling.

Refer to "CHANGING THE COOLANT" in chapter 3.

FUEL INJECTION

© Ignition coil ©Air filter case @ Intake temperature sensor © Fuel delivery hose © Fuel tank © Fuel pump © Fuel return hose

FUEL INJECTION SYSTEM SYSTEM

©Intake air pressure (13Coolant temperature 19Atmospheric pressure sensor sen-

9 Throttle position sor

(10 Fuel injector 11 Catalytic converter (12 Crankshaft position sensor sensor (14 Spark plug (15 Cylinder identification sensor (16 Pressure regulator (17 Battery (18ECU

sensor

Fuel injection system relay

Engine trouble warning light

Lean angle cut-off switch

_

FI

0 Main switch Battery Fuse (main) Fuse (fuel injection) Fuse (ignition) (H Starting circuit cut-off relay Sidestand switch Fuel pump © ECU

Ignition coil Spark plug Fuel injector Neutral switch Crankshaft position sensor Intake air temperature sensor Coolant temperature sensor Throttle position sensor Intake air pressure sensor Atmospheric pressure sensor Cylinder identification sensor Speed sensor Lean angle cut-off switch Multi-function meter Engine stop switch

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