Nm 10 mCkg Oil level switch bolt 10 Nm 10 mCkg

Remove the parts in the order listed. Refer to CYLINDERS AND PISTONS. Refer to TIMING PLATE AND PICKUP COIL. For installation, reverse the removal pro CLoosen each bolt 1 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. CLoosen the bolts in decreasing numerical order (refer to the numbers in the illustration). CThe numbers embossed on the crankcase indicate the crankcase tightening sequence. 2. Place the engine upside down.

Periodic Maintenancelubrication Intervals

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by Yamaha dealer as they require special tools, data and technical skills. Check fuel hoses and vacuum hose for cracks or damage. Check operation, fluid level and vehicle for fluid leakage. (See NOTE.) Check operation, fluid level and vehicle for fluid leakage....

Removing the oil pan

Oil level switch O-ring Oil pan Dowel pin Gasket Relief valve O-ring Relief valve O-ring Oil strainer Oil strainer housing Gasket Remove the parts in the order listed. Refer to ENGINE. Refer to REMOVING INSTALLING THE OIL PAN. Refer to INSTALLING THE OIL STRAINER. For installation, reverse the removal procedure.

Clutch

Remove the parts in the order listed. For installation, reverse the removal Remove the parts in the order listed. Refer to INSTALLING THE CLUTCH. n Refer to REMOVING INSTALLING THE CLUTCH. Clutch spring plate seat Friction plates (narrow) Refer to REMOVING INSTALLING THE CLUTCH. For installation, reverse the removal procedure. 1. Straighten the lock washer tab. While holding the clutch boss (2 with the universal clutch holder, loosen the clutch boss nut. Universal clutch holder (3) 90890-04086...

Replacing The Rear Brake Pads Note

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. Cbrake pad cover Cbrake pad clips Cbrake pad pins Cbrake pad spring 4. Measure Cbrake pad wear limit Out of specification Replace the brake pads as a set. 5. Install Cbrake pad shims (onto the brake pads) Cbrake pads Cbrake pad spring

Caution

Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate Gnner tube's outer surface Yamaha fork and shock oil 10W or equivalent Damper rod bolt 30 Nm (3.0 mCkg) LOCTITE lolding the damper rod with the damper lder and T-handle , tighten the r rod bolt. 4. Install Couter tube bushing Cseal spacer (2) Coil seal (with the fork seal driver weight and adapter )

Brake caliper bolt 40 Nm 40 mCkg

Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. Cbrake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. Brake lever Brake switch lead Front brake switch Union bolt Copper washers Brake hose Master cylinder bracket Master cylinder Remove the parts in the order listed. Drain Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR _...

Faulty Lighting And Signaling Systems

CWrong headlight bulb CToo many electrical accessories CHard charging CIncorrect connection CIncorrectly grounded circuit CPoor contacts (main or light switch) CBurnt-out headlight bulb CWrong headlight bulb CFaulty battery CFaulty rectifier regulator CIncorrectly grounded circuit CFaulty main switch CFaulty light switch CHeadlight bulb life expired CWrong tail brake light bulb CToo may electrical accessories CIncorrect connection CBurnt-out tail brake light bulb CWrong tail brake light bulb...

Be sure to install the starter clutch roller to the starter clutch drive gear so that the circlip is outside

Remove the parts in the order listed. Refer to STARTER CLUTCH. Refer to REMOVING INSTALLING THE CRANKSHAFT ASSEMBLY. For installation, reverse the removal procedure. Connecting rod bolt Coonecting rod Connecting rod cap Connecting rod bearing Remove the parts in the order listed -i Refer to INSTALLING THE -1 CONNEECTING RODS. Refer to REMOVING INSTALLING THE _ CONNECTING RODS. For installation, reverse the removal procedur. 1. Remove ccrankshaft assembly ccrankshaft journal upper bearings (from...

Checking The Cylinders And Pistons

Piston Ring Gap Setting Yamaha Fazer

The following procedure applies to all of the cylinders and pistons. 1. Check Cpiston wall ccylinder wall Vertical scratches Replace the cylinder, and replace the piston and piston rings as a set. a. Measure cylinder bore C with the cylinder bore gauge. 20 mm from the top of the cylinder Measure cylinder bore C by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. b. If out of specification, replace the cylinder, and replace the...

General Tightening Torques

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. A...

Specifications General Specifications

600 3tb Oil Diagram

120 70ZR17 (58W) 120 70ZR17 M C (58W) 180 55ZR17 (73W) 180 55ZR17 M C (73W) *Load is the total weight of cargo, rider, passenger, and accessories. Cylinder Bore size Taper limit Out of round limit Wear limit Camshaft Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions Chain drive (Center) 25.000 - 25.021 mm 24.967 - 24.980 mm 0.020 - 0.054 mm A B A B 35.95 - 36.05 mm 28.058 - 28.158 mm 35.95 - 36.05 mm 28.045 - 28.145 mm 35.85 mm 27.958 mm 35.85...

Installing The Connecting Rods

Lubricate Cbolt threads Chut seats with the recommended lubricant 2. Lubricate Ccrankshaft pins Cbig end bearings Connecting rod inner surface with the recommended lubricant 3. Install Cbig end bearings Connecting rods Connecting rod caps onto the crankshaft pins Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. CBe sure to reinstall each big end bearing in its original place. CMake sure that the Y marks on the connecting rods face...

Note

Yamaha Warrior 350 Timing Diagram

The timing chain tensioner teeth should face down. Timing chain tensioner bolt 10 Nm 1.0 mckg d. Install the springs , washer and cap bolt Cap bolt timing chain tensioner 20 Nm 2.0 mckg Out of alignment Reinstall the camshafts by referring the above steps. a. Turn the crankshaft counterclockwise several times until the TDC mark on the timing plate is aligned with the stationary pointer. b. Check if both the camshaft timing punch marks are aligning with the camshaft cap hole .

Measuring The Engine Oil Pressure Adjusting The Clutch Lever

80 kPa 0.8 kg cm2, 0.8 bar Engine speed Approx. 1000 r min Engine oil temperature 70 x 80 C 158 x 176 F Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Leaking oil passage Faulty oil filter Oil viscosity too high 1. Adjust clutch lever position distance from the handlebar grip to the clutch lever a. While pushing the clutch lever forward, turn the adjusting dial until the clutch lever is in the desired position. Be sure to align the setting on the adjusting...

Valve spring compressor 9089004019

Remove CUpper spring seat CValve springs COil seal Clower spring seat CValve Identify the position of each part very carefully so that it can be reinstalled in its original place. CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure Cvalve-stem to valve guide clearance Valve-stem to valve-guide clearance Valve guide inside diameter -Valve stem diameter Valve-stem to valve-guide clearance Intake 0.010 x 0.037 mm Limit 0.08 mm...

Charging method using a variablevoltage charger

Szr 660 Battery

Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Set the charging voltage to 16 x 17 V. If the charging voltage is lower charging will be insufficient, if it is higher, the battery will be over-charged.

Checking The Timing Chain Tensioner

Motor Yamaha Warrior Timing Chain

Ctiming chain tensioner Cracks damage Replace. cone-way cam operation Rough movement Replace the timing chain tensioner housing. 3. Check ccap bolt ccopper washer cspring ctiming chain tensioner rod Damage wear Replace the defective part -s . CBe sure to set the sprockets in the specified position as shown in the figure. CTemporarily tighten the bolts in this stage. 2. Install ccamshaft exhaust ccamshaft intake a. Turn the crankshaft counterclockwise until the TDC mark is aligned with the...

Camshaft cap bolt 12 Nm 12 m kg

Remove the camshaft caps and then measure the width of the Plastigauge . 5. Measure CCamshaft journal diameter Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.967 x 24.980 mm Camshaft journal diameter 24.967 x 24.980 mm

Checking The Camshafts

Blue discoloration pitting scratches Replace the camshaft. ccamshaft lobe dimensions and Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake exhaust Wear limit lt 28.15 mm gt Wear limit lt 35.85 mm gt 3. Measure CCamshaft runout Out of specification Replace. 4. Measure CCamshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance Camshaft-journal-to-camshaft-cap clearance a. Install...

Yamaha Xjr 1300

Xjr 1300 Valve Clearance

Remove the parts in the order listed. Refer to SEAT, SIDE COVER AND FUEL TANK. For installation, reverse the removal procedure. Remove the parts in the order listed. For installation, reverse the removal procedure. 1. Align oT mark on the timing plate with the stationary pointer on the pickup coil base plate a. Turn the crankshaft counterclockwise. b. When piston 1 is at TDC on the compression stroke, align the T mark with the pickup coil mark . TDC on the compression stroke can be found when...

Charging method using a constantvoltage charger

Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Is the amperage higher than the standard charging amperage written on the battery

Lubrication Diagrams

Yamaha Xvz Battery Box Diagram

Camshaft intake 2 Camshaft exhaust 3 Main gallery Oil strainer 5 Oil pump 6 Main axle Crankshaft Oil cooler Starter clutch Main axle Drive axle Oil pump Oil pan Relief valve Main gallery Camshaft Crankshaft Oil pump Oil filter IB Align the white tape on the wire- Route the wireharness and starter motor cable in front of the reservoir tank bracket and the battery negative - lead behind the reservoir tank bracket. And fasten them with a plastic band. Fasten the wireharness, neutral lead,...

Engine

Cbr Tdc Marking

The following procedure applies to all of the valves. Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center TDC on the compression stroke. Refer to SEAT, SIDE COVER AND FUEL TANK. 4. Measure valve clearance Out of specification Adjust. Intake valve 0.11 x 0.15 mm Exhaust valve 0.16 x 0.20 mm Intake valve 0.11 x 0.15 mm Exhaust valve 0.16 x 0.20 mm a. Turn the crankshaft...

Yamaha Xjr 1300 Tuning

Tuning Yamaha Xjr 1300

Never go beyond the maximum or minimum adjustment positions. Adjust the spring preload with the special wrench and extension bar in eluded in the owner's tool kit. a. Turn the spring seat in direction or . a. Turn the spring seat in direction or . Spring preload is increased suspension is harder . Spring preload is decreased suspension is softer . Adjusting positions Standard 1 Minimum 1 Maximum 3 The following procedure applies to both of the tires.

Periodic Inspection And Adjustment

PERIODIC MAINTENANCE LUBRICATION INTERVALS 3-1 SEAT SIDE COVER AND FUEL TANK 3-3 ENGINE ADJUSTING THE VALVE CLEARANCE 3-4 SYNCHRONIZING THE ADJUSTING THE IDLING SPEED 3-10 ADJUSTING THE THROTTLE CABLE FREE PLAY 3-11 CHECKING THE SPARK PLUGS 3-13 CHECKING THE IGNITION MEASURING THE COMPRESSION PRESSURE 3-14 CHECKING THE ENGINE OIL LEVEL 3-16 CHECKING THE ENGINE MEASURING THE ENGINE OIL PRESSURE 3-18 ADJUSTING THE CLUTCH LEVER 3-19 CHECKING THE CLUTCH FLUID LEVEL 3-20 BLEEDING THE HYDRAULIC...

Checking The Connections

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect CDead ccoupler Connector 2. Check Clead CCoupler CConnector Moisture Dry with an air blower. Rust stains Connect and disconnect several times. 3. Check call connections Loose connection Connect properly. If the pin on the terminal is flattened, bend it up. 4. Connect CDead ccoupler cconnector Make sure that all connections are tight. 5. Check ccontinuity with a pocket tester Of there is no continuity, clean...

Xjr1300 Throttle Free Play

After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. CHECKING THE SPARK PLUGS CHECKING THE IGNITION TIMING The following procedure applies to all of the spark plugs. Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 3. Check cspark plug type Incorrect Change. Spark plug type...

General Specifications

Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2175 mm GB D NL B F E P I GR SF AUS Basic weight With oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Compression pressure STD Starting system Lubrication system Forward-inclined parallel 4-cylinder 1050 kPa 10.5 kg cm2,10.5 bar at 400 r min Electric starter Wet sump Oil type or grade Engine oil -20 -10 Engine oil Periodic oil change With...

Important Information

PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This...

Changing The Engine Oil Measuring The Engine Oil Pressure

Without oil filter element replacement 3 L With oil filter element replacement 3.35 L 10. Start the engine, warm it up for several minutes, and then turn it off. Refer to CHECKING THE ENGINE OIL LEVEL. Below the minimum level mark Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off.

Turns out

Yamaha Vmax Throttle Screw

Turn the throttle stop screw in direction or until the specified engine idling speed is obtained. 5. Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play at the flange of the throttle grip 3 x 5 mm Throttle cable free play at the flange of the throttle grip 3 x 5 mm

S

Ignitor Unit Assy Xjr1300

Dimensions B x T End gap installed Side clearance installed Oil ring Dimensions B x T End gap installed Side clearance Crank width A Assembly width B Runout limit C Big end side clearance D Journal oil clearance Lubrication system Oil filter type Oil pump type Tip clearance Housing and rotor clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure hot Pressure check location Paper type Trochoid type 0.12 x 0.17 mm 0.03 x 0.08 mm 0.03 x 0.08 mm 180 x...

Maintenance Specifications

Cylinder Bore size Taper limit Out of round limit Wear limit Camshaft Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions Chain drive Center 25.000 x 25.021 mm 24.967 x 24.980 mm 0.020 x 0.054 mm A B C A B 35.95 x 36.05 mm 28.248 x 28.348 mm 7.95 x 8.05 mm 35.95 x 36.05 mm 28.248 x 28.348 mm 7.95 x 8.05 mm Cam chain Cam chain type No. of links Cam chain adjustment method Seat Width 28.9 x 29.1 mm 24.9 x 25.1 mm 1.98 x 2.55 mm 1.98 x 2.55 mm 0.9...

Special Tools

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Exhaust amp steering nut wrench Ring nut wrench This tools are used to loosen and tighten the steering ring nut. This tool is used to remove the piston pins. This tool is used to measure the...