Engine Mechanical:
Complete disassembly, assembly, inspection, and repair procedures for engine internals, cylinders, pistons, crankshaft, camshafts, valve train, etc.
Fuel System:
Fuel injection system (EFI), throttle bodies, fuel pump, fuel injectors, fuel lines, evaporative emission control (EVAP) system.
Cooling System:
Radiator, coolant, cooling fan, water pump, thermostat, coolant passages.
Ignition System:
Ignition coils, spark plugs, ignition control unit (ICU), wiring.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter, oxygen sensors.
Transmission:
5-speed sequential gearbox, clutch assembly, shift mechanism, lubrication.
Drivetrain:
Shaft drive system, final drive, universal joints, rear differential (if applicable).
Chassis Frame:
Frame inspection, welding, repair procedures, steering head assembly.
Suspension Front:
Telescopic front forks (standard), upside-down forks (AE model), damping adjustments, seals, springs.
Suspension Rear:
Monoshock rear suspension, linkage system, preload adjustments, damping adjustments (manual on A, electronic on AE).
Brakes Front:
Dual disc brakes, calipers, master cylinders, brake lines, ABS system (if equipped).
Brakes Rear:
Single disc brake, caliper, master cylinder, brake lines, ABS system (if equipped).
Wheels Tires:
Wheel bearings, tire replacement, wheel balancing, specifications.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn.
Instrumentation:
Speedometer, tachometer, fuel gauge, LCD display, warning lights, diagnostic codes.
Control Systems:
Handlebars, throttle control, clutch lever, brake levers, gear shift lever, footpegs.
Bodywork Fairings:
Fairing removal and installation, cosmetic repairs, seat, fuel tank, storage compartments.
Electronic Suspension:
AE Model Specific: Electronic suspension control unit, actuators, sensors, adjustment procedures.
Scheduled Maintenance:
Detailed procedures for oil changes, filter replacements, chain/shaft drive inspection, brake fluid flush, coolant flush, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnostic procedures for common problems, error code interpretation, electrical diagnostics, engine performance issues.
Engine Repair:
Complete rebuild procedures, valve clearance adjustment, piston ring replacement, gasket replacement, timing chain inspection.
Transmission Repair:
Gearbox inspection, seal replacement, clutch plate replacement, shift drum and fork inspection.
Brake System Repair:
Brake pad replacement, caliper overhaul, master cylinder rebuild, brake line replacement, ABS bleeding procedures.
Suspension Overhaul:
Fork seal replacement, shock absorber rebuild, linkage bearing service.
Electrical Diagnostics:
Wiring diagrams, troubleshooting electrical faults, charging system testing, starter circuit testing.
Fuel System Service:
Injector cleaning, throttle body synchronization, fuel pressure testing.
Bodywork Refurbishment:
Fairing panel removal, installation, minor bodywork repairs.
Special Tool Usage:
Identification and usage instructions for specialized Yamaha tools required for specific repair procedures.
Depth:
Comprehensive: Covers everything from basic maintenance and fluid checks to complete engine and transmission rebuilds, including electrical system diagnostics.
Diagnostic Capabilities:
Detailed troubleshooting trees, diagnostic trouble codes (DTCs), and electrical schematics for pinpointing issues.
Specifications Accuracy:
Provides precise torque values, clearances, fluid capacities, and electrical specifications required for accurate repairs.
Oil Change:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Air Filter Check:
Every 6,000 km (3,700 mi) or 6 months.
Spark Plug Replacement:
Every 12,000 km (7,500 mi) or 12 months.
Valve Clearance Check:
Every 24,000 km (15,000 mi) or 24 months.
Engine Oil:
Yamalube 4 (10W-40) or Yamalube 4 (20W-50) or equivalent API SG, SF, or SG/CD SAE 10W-40 or 20W-50.
Coolant:
Permanent type antifreeze coolant (high-quality ethylene glycol based) with demineralized water in a 50:50 ratio. Refer to manual for specific Yamaha coolant.
Common Complaints:
While generally reliable, some owners report occasional issues with the electronic suspension (AE model) requiring recalibration or sensor checks. Clutch slave cylinder leaks can occur over time. Some models may experience stator failures.
Diagnostic Importance:
The service manual is crucial for diagnosing and rectifying these potential issues effectively.