Page 244 of 457
5-22
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the cylinder head
Engine
Intake camshaft
Exhaust camshaft
Cylinder head
Cylinder head gasket
Dowel pin
Coolant pipe
O-ring
Thermo wax out let hose1
1
2
1
1
1Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
For installation, reverse the removal
procedure.
18 Nm (1.8 mkg, 13 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
19 Nm (1.9 mkg, 14 ftlb)
67 Nm (6.7 mkg, 48 ftlb)
1st
2nd
10 Nm (1.0 mkg, 7.2 ftlb)
CYLINDER HEADENG
EAS00221
CYLINDER HEAD
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Page 329 of 457
6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings
Bottom cowling
Coolant
Fuse box stay
Coolant reservoir hose
Radiator
Radiator fan motor
Radiator inlet hose1
1
1
2
1Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “COWLINGS” in chapter 3.
Refer to “SEATS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
5 Nm (0.5 mkg, 3.6 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
RADIATORCOOL
EAS00454
COOLING SYSTEM
RADIATOR
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Page 332 of 457
6-4
RADIATORCOOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
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”.
ProCarManuals.com
Page 335 of 457
6-7
OIL COOLERCOOL
63 Nm (6.3 mkg, 46 ftlb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:
oil cooler
Cracks / damage Replace.
2. Check:
oil cooler inlet hose
oil cooler outlet hose
Cracks / damage / wear Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:
mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
O-ring
New
oil cooler
1
washer 2 New
bolt
3
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 proper-
ly.
Align the projection
a on the oil cooler with the
slot
b in the crankcase.
3. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Check:
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”.
ProCarManuals.com
Page 336 of 457
6-8
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the thermostat assembly
Rider seat
Fuel tank
Air filter case
Coolant
Thermostat assembly outlet hose
Thermostat assembly breather hose
Thermostat assembly
Thermostat assembly inlet hose
Band1
1
1
1
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter3.
For installation, reverse the removal
procedure.
THERMOSTATCOOL
EAS00460
THERMOSTAT
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Page 339 of 457
6-11
THERMOSTATCOOL
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
EAS00464
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
thermostat housing
1
thermostat 2
O-ring New 3
thermostat housing cover 4
Install the thermostat with its breather hole a
facing up.
EAS00466
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
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”.
ProCarManuals.com
Page 340 of 457
6-12
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
1
2
3
4Removing the impeller shaft
Oil / water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)1
1
2
1
Remove the parts in the order listed.
The water pump and oil pump are com-
bined into one unit (oil / water pump as-
sembly).
It is not necessary to remove the impeller
shaft unless the coolant level is extreme-
ly low or coolant leaks from the oil pan.
Refer to “OIL PAN AND OIL PUMP” in
chapter 5.
12 Nm (1.2 mkg, 8.7 ftlb)
NOTE:
EAS00468
WATER PUMP
IMPELLER SHAFT
ProCarManuals.com
Page 343 of 457
6-15
WATER PUMPCOOL
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
oil seal
New 1
(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.
2. Install:
water pump seal
New 1
Never lubricate the water pump seal surface
with oil or grease.
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
4
90890-04078, YM-33221
Middle driven shaft bearing
driver
5
90890-04058, YM-04058
Yamaha bond #1215
90890-85505
Quick gasket
ACC-11001-05-01
APush down.
3. Install:
rubber damper
New 2
rubber damper holder New 1
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
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