1 - 15
MOTORCYCLE CARE AND STORAGE
Care
The exposure of its technology makes
a motorcycle charming but also vulner-
able. Although high-quality compo-
nents are used, they are not all rust-
resistant. While a rusty exhaust pipe
may remain unnoticed on a car, it does
look unattractive on a motorcycle. Fre-
quent and proper care, however, will
keep your motorcycle looking good, ex-
tend its life and maintain its perfor-
mance. Moreover, the warranty states
that the vehicle must be properly taken
care of. For all these reasons, it is rec-
ommended that you observe the fol-
lowing cleaning and storing
precautions.Before cleaning
1. Cover up the muffler outlet with a
plastic bag.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.Cleaning
After normal useRemove dirt with warm water, a neutral
detergent and a soft clean sponge,
then rinse with plenty of clean water.
Use a tooth or bottle brush for hard-to-
reach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few min-
utes before cleaning.
MOTORCYCLE CARE AND STORAGE
ECA00010
CAUTION:
lAvoid using strong acidic
wheel cleaners, especially on
spoked wheels. If you do use
such products for hard-to-re-
move dirt, do not leave it on any
longer than instructed, then
thoroughly rinse it off with wa-
ter, immediately dry the area
and apply a corrosion protec-
tion spray.
lImproper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
lDo not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
lDo not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
bearings, swingarm bearings,
forks and brakes), electric com-
ponents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
lFor motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure they do not
leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
lDo not rub the frame, swingarm
and other similar matte metal
parts with a cloth (neither one
dampened with solvents or
gasoline nor a dry one), as this
may deteriorate their finish.
Wash off dirt with water only.
For hard-to-remove dirt, add a
mild detergent and rub only
lightly.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)
ENGINE SPECIFICATIONS
SPEC
2 - 2
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC ----
Displacement 749 cm
3
----
Cylinder arrangement Forward-inclined parallel 4-cylinder ----
Bore
´
stroke 72
´
46 mm (2.83
´
1.81 in) ----
Compression ratio 11.4:1 ----
Engine idling speed 1,000 ~ 1,200 r/min ----
Vacuum pressure at engine idling
speed15.8 ~ 18.4 kPa
(120 ~ 140 mm Hg, 4.72 ~ 5.51 in Hg)----
Standard compression pressure
(at sea level) 157 kPa
(1.57 kgf/cm
2
, 22.3 psi) at 500 r/min----
Fuel
Recommended fuel Premium unleaded gasoline ----
Fuel tank capacity
Total (including reserve) 23 L (20.2 Imp qt, 24.3 US qt) ----
Reserve only 4.8 L (4.22 Imp qt, 5.07 US qt) ----
Engine oil
Lubrication system Wet sump ----
Recommended oil
Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40˚F/5˚C or above)
(Non-Friction modified)
Yamalube 4 (10W40) or SAE 10W40 type
SE motor oil (60˚F/15˚C or below)
(Non-Friction modified)----
Quantity
Total amount 3.6 L (3.2 Imp qt, 3.8 US qt) ----
Without oil filter cartridge
replacement2.6 L (2.3 Imp qt, 2.7 US qt) ----
With oil filter cartridge replace-
ment2.8 L (2.5 Imp qt, 3.0 US qt) ----
Oil pressure (hot) 40 kPa (0.4 kgf/cm
2
, 5.69 psi) at
1,100 r/min ----
Relief valve opening pressure 480 ~ 560 kPa
(4.8 ~ 5.6 kgf/cm
2
, 68.3 ~ 79.7 psi)----
2
ENGINE SPECIFICATIONS
SPEC
2 - 3
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 180 ~ 220 kPa
(1.8 ~ 2.2 kgf/cm
2
, 25.6 ~ 31.3 psi)----
Oil pump
Oil pump type Trochoidal ----
Inner rotor-to-outer rotor tip clear-
ance0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ----
Outer rotor-to-oil pump housing
clearance0.03 ~ 0.08 mm (0.001 ~ 0.003 in) ----
Cooling system
Radiator capacity 2.75 L (2.42 Imp qt, 2.91 US qt)
Radiator cap opening pressure 95 ~ 125 kPa
(0.95 ~ 1.25 kgf/cm
2
, 13.1 ~ 17.8 psi)----
Upper radiator core
Width 414 mm (16.3 in) ----
Height 248 mm (9.76 in) ----
Depth 24 mm (0.94 in) ----
Lower radiator core
Width 211 mm (8.31 in) ----
Height 158 mm (6.22 in) ----
Depth 24 mm (0.94 in) ----
Coolant reservoir
Capacity 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 88/47
´
28/25 (2.097) ----
Maximum impeller shaft tilt ---- 0.15 mm
(0.006 in)
Starting system type
Electric starter
Spark plugs
Model (manufacturer)
´
quantity R0256R-10 (NGK)
´
4 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
Cylinder head
Maximum warpage ---- 0.06 mm
(0.0024 in) Item Standard Limit
CHASSIS SPECIFICATIONSSPEC
2 - 14
Steering
Steering bearing type Angular ball bearings ----
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly
typeCoil spring/gas-oil damper ----
Rear shock absorber assembly
travel63 mm (2.48 in) ----
Spring
Free length 160 mm (6.30 in) ----
Installed length 146 mm (5.75 in) ----
Spring rate (K1) 95 N/mm (9.69 kgf/mm, 543 lb/in) ----
Spring stroke (K1) 0 ~ 63 mm (0 ~ 2.48 in) ----
Optional spring available No ----
Standard spring preload gas/air
pressure 1,200 kPa (12 kgf/cm
2, 171 psi) ----
Spring preload adjusting positions
Minimum 0 [11 mm (0.43 in)] ----
Standard 6 [14 mm (0.55 in)] ----
Maximum 20 [21 mm (0.84 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 50 ----
Standard* 10 ----
Maximum* 0 ----
Compression damping adjusting
positions
Minimum* 25 ----
Standard* 10 ----
Maximum* 0 ----
* from the fully turned-in position
Swingarm
Free play (at the end of the swing-
arm)
Radial ---- 1 mm
(0.04 in)
Axial ---- 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 50ZVM (DAIDO) ----
Link quantity 118 ----
Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) ----
Maximum ten-link section 150.1 mm (5.91 in) ----Item Standard Limit
2 - 19
SPEC
Shift shaft cover Bolt M6 6 12 1.2 8.7
Oil baffle plate Bolt M6 5 10 1.0 7.2
LT
Timing mark accessing screw – M8 1 15 1.5 11
Starter clutch Bolt M6 3 12 1.2 8.7
LT
Clutch boss Nut M20 1 70 7.0 50Use a lock
washer.
Clutch spring Bolt M6 6 8 0.8 5.8
Drive sprocket Nut M18 1 70 7.0 50Use a lock
washer.
Main axle bearing housing Screw M6 3 12 1.2 8.7
LT
Shift drum retainer Bolt M6 2 10 1.0 7.2LT
Shift shaft spring stopper Bolt M8 1 22 2.2 16LT
Shift rod locknut Nut M6 2 7 0.7 5.1
Shift arm Bolt M6 1 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2
LT
Neutral switch – M10 1 20 2.0 14
Pickup coil Screw M5 2 4 0.4 2.9
LT
Thermo switch – M16 1 23 2.3 17
Camshaft sensor Bolt M6 1 10 1.0 7.2
LT
Speed sensor Bolt M6 1 10 1.0 7.2LT
Coolant temperature sensor – M12 1 18 1.8 13
Intake air temperature sensor – M12 1 18 1.8 13
Intake air pressure sensor Screw M5 2 5 0.5 3.6
LT
Atmospheric pressure sensor Screw M5 2 5 0.5 3.6LT
Air funnel Bolt M6 8 10 1.0 7.2LT
Throttle body assembly Bolt M6 16 10 1.0 7.2
Injector 2 cover Bolt M5 8 8 0.8 5.8
LT
Fuel distributor Bolt M6 6 10 1.0 7.2LT
Injector fuel pipe 1,3 and 4 Union bolt M12 3 30 3.0 22
Injector fuel pipe 2 – M12 1 30 3.0 22
Fuel hose joint pipe Bolt M5 1 6 0.6 4.3
LT
Pressure sensor bracket Bolt M5 2 8 0.8 5.8LT
Item Fastener Thread size Q’tyTightening torque
Remarks
Nm m·kgf ft·lb
TIGHTENING TORQUES
2 - 24
SPEC
OIL FLOW CHART
Pressure feed
Timing chain area camshaft
Valve lifter Check bolt
Piston
Connecting rod
Big end bearing
Nozzle
Nozzle
Back torque limiter clutch
Starter clutch Main axleMain gallery
Drive axle
Oil filter cartridge
Oil cooler
Relief valve
Oil pump
Oil strainer
Oil pan
Drain bolt Main axle gears
Drive axle gearsCrankshaft journal (#2, #4)
Crankshaft journal (#3, #5)Crankshaft journal (#1)
OIL FLOW CHART
3 - 15
CHK
ADJ
SYNCHRONIZING THE THROTTLE BODIES
4. Install:
• vacuum gauge attachments
(into the bolt holes)
• vacuum gauge
(onto the vacuum gauge attachments)
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Disconnect the ignition coil coupler and
remove the ignition coil 1 of cylinder
#1, remove the rubber cover 2, and
wrap the engine tachometer lead sev-
eral times around section a of the igni-
tion coil. Then, install the ignition coil
and connect the ignition coil coupler.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
6. Start the engine and let it warm up for
several minutes.
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-06760
1 1
2
2
a
a
7. Measure:
• engine idling speed
Out of specification ® Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
1,000 ~ 1,200 r/min
8. Adjust:
• throttle body synchronization
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Turn the air screws 1 to adjust the
vacuum pressure of all throttle bodies
to specification.
NOTE:
Do not turn the synchronizing screws.1 11 1
3 - 21
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
3. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
• ignition coil
4. Remove:
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
5. Install:
• compression gauge 1
• adapter 2
Compression gauge
90890-03081
Adapter
90890-04136
1
1
2
2
6. Measure:
• compression pressure
Out of specification ® Refer to steps
(c) and (d).
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the com-
pression gauge stabilizes.
Compression pressure (at sea
level)
Minimum
1,500 kPa
(15.0 kg/cm
2, 213 psi)
Standard
1,600 kPa
(16.0 kg/cm
2, 228 psi)
Maximum
1,700 kPa
(17.0 kg/cm
2, 242 psi)