Caution Tcg
A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise...
Lubrication Points And Lubricant Types
Steering bearings and bearing races upper and lower Front wheel oil seal right and left Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Relay arm, connecting rod and rear shock absorber collar Swingarm head pipe end, oil seal and bush Oil seal relay arm, connecting arm and rear shock absorber Engine mount bolts rear upper and...
Checking The Connections
Check the leads, couplers, and connectors for stains, rust, moisture, etc. Moisture Dry with an air blower. Rust stains Connect and disconnect several times. Loose connection Connect properly. If the pin on the terminal is flattened, bend it up. Make sure all connections are tight. If there is no continuity, clean the terminals. When checking the wire harness, perform steps 1 to 3 . As a quick remedy, use a contact revitalizer available at most part stores.
Features
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same volume of intake air, the fuel volume requirement...
Synchronizing The Throttle Bodies Note
Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE Place the motorcycle on a suitable stand. Refer to AIR FILTER CASE. 3. Remove synchronizing hose onto the synchronizing hose digital tachometer near the spark plug Refer to AIR FILTER CASE. 6. Start the engine and let it warm up for several minutes. Refer to ADJUSTING THE ENGINE IDLING...
Synchronizing The Throttle Bodies Adjusting The Engine Idling Speed
Make sure that the vacuum pressure is within 10. Stop the engine and remove the measuring equipment. Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play at the flange of the throttle grip 6 8 mm 0.24 0.31 in Refer to AIR FILTER CASE. ADJUSTING THE ENGINE IDLING SPEED NOTE - Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, and the engine should have adequate compression. 1. Start the engine and let it warm up for...
Checking The Spark Plugs Measuring The Compression Pressure
spark plug gap with a wire Thickness gauge Out of specification Regap. Spark plug gap 0.6 0.7 mm 0.0236 0.0276 in Spark plug gap 0.6 0.7 mm 0.0236 0.0276 in spark plug IX113 Nm 1.3 m kg, 9.4 fHb Before installing the spark plug, clean the spark plug and gasket surface. Refer to AIR FILTER CASE. The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2....
General Tightening Torque Specifications
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...
Changing The Coolant
left side cowling Refer to COWLINGS. coolant reservoir tank cover
Checking The Cooling System Changing The Coolant
water jacket outlet joint 7 water pump outlet hose Cracks damage Replace. Refer to COOLING SYSTEM in chapter 6. bottom cowling Refer to COWLINGS.
Chassis Specifications
250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi Tire pressure cold 0 90 kg 0 198 lb 90 193 kg 198 426 lb USA except for CAL 90 192 kg 198 423 lb CAL High-speed riding Min. tire tread depth 180 55 ZR17 M C 73W Pilot SPORT B MICHELIN D208L DUNLOP 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 290 kPa 2.9 kgf cm2, 2.9 bar, 41.3 psi 290 kPa 2.9 kgf cm2, 2.9 bar, 41.3 psi 250 kPa 2.5 kgf cm2, 2.5 bar,...
Checking The Engine Oil Level Changing The Engine Oil
At 5 C 40 F or higher A Yamalube 4 20W40 or SAE 20W40 type SE motor oil At 15 C 60 F or lower B Yamalube 4 10W30 or SAE 10W30 type SE motor oil Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. 1. Start the engine, warm it up for several minutes, and then turn it off....
Note
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 AIR FILTER CASE. Refer to THROTTLE BODIES in chapter 7. Refer to AIR INDUCTION SYSTEM in chapter 7. Refer to RADIATOR in chapter 6. Refer to CAMSHAFT in chapter 5. 4. Measure valve clearance Out of specification Valve clearance cold Intake valve 0.13 - 0.20 mm 0.0051 - 0.0079 in...
Adjusting The Throttle Cable Free Play
3. Adjust throttle cable free play When the throttle is opened, the accelerator cable is pulled. b. Turn the adjusting nut in direction or to take up any slack on the decelerator cable. Throttle cable free play is increased. Throttle cable free play is decreased. If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. b. Turn the adjusting nut 2 in direction or until the specified throttle cable free play...
Engine Specifications
Standard compression pressure at sea level Liquid-cooled, 4-stroke, DOHC 600 cm3 36.61 cu.in Forward-inclined parallel 4-cylinder 65.5 x 44.5 mm 2.58 x 1.75 in 12.4 1 1,550 kPa 15.50 kg cm2,15.50 bar, 220.46 psi at 400 r min Recommended fuel Fuel tank capacity Total including reserve Reserve only 17 L 3.74 Imp gal, 4.49 US gal 3.5 L 0.77 Imp gal, 0.92 US gal Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature...
Cable Routing
Right handlebar switch lead Clutch cable Main switch lead and left handlebar switch lead Throttle cable return side Throttle cable pull side Front brake hoses Throttle cables Joint A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward. O Pass the clutch cable through the guide. 0 Plastic locking tie shall be positioned at 10 mm 0.39 in. below...
Electrical Specifications
K003T20191 MITSUBISHI 0.2898 - 0.3542 Q at 80 C 176 F CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS
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. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. For U.S.A. and Canada, use part number starting with YM-, YU-, or ACC-. For others, use part number starting with...