1980 fleetwood terry travel trailer owners manual
LINK 1 ENTER SITE >>> Download PDF
LINK 2 ENTER SITE >>> Download PDF
File Name:1980 fleetwood terry travel trailer owners manual.pdf
Size: 1431 KB
Type: PDF, ePub, eBook
Category: Book
Uploaded: 4 May 2019, 15:15 PM
Rating: 4.6/5 from 603 votes.
Status: AVAILABLE
Last checked: 10 Minutes ago!
In order to read or download 1980 fleetwood terry travel trailer owners manual ebook, you need to create a FREE account.
eBook includes PDF, ePub and Kindle version
✔ Register a free 1 month Trial Account.
✔ Download as many books as you like (Personal use)
✔ Cancel the membership at any time if not satisfied.
✔ Join Over 80000 Happy Readers
1980 fleetwood terry travel trailer owners manualAny reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Off-road use on public lands may also be illegal. Please check local regula- tions before riding. Die Benutzung dieses TION, UNIQUEMENT SUR CIRCUIT LE COMPETIZIONI SU CIRCUITI. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. Sollten Sie versehentlich CARE DANNI PERSONALI.NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings. When washing the machine with high pressured water, cover the parts follows. Silencer end Air filter intake hole Water pump housing hole at the bottom Carburetor accelerator pump. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.http://pretaporter-pegah.com/userfiles/does-manual-car-have-transmission-fluid.xml
- Tags:
- 1980 fleetwood terry travel trailer owners manual, 1980 fleetwood terry travel trailer owners manual 1, 1980 fleetwood terry travel trailer owners manual pdf, 1980 fleetwood terry travel trailer owners manual free, 1980 fleetwood terry travel trailer owners manual download.
YM-1423, 90890-01423 Damper rod holder YM-1423 90890-01423 Use this tool to remove and install the damper rod. YM-01442, 90890-01442 Fork seal driver YM-01442. YM-01442, 90890-01442 Gabeldichtring-Treiber YM-01442 90890-01442 Zum Einbau der Gabeldichtringe. YU-3112-C, 90890-03112 Taschen-Multimeter YU-3112-C. La forma e il numero di pezzo utilizzato per l’attrezzo speciale differiscono da paese a paese, pertanto ne vengono indicati due tipi. YM-1423, 90890-01423 Utensile di blocco dell’asta ammortizzatore YM-1423 90890-01423 Utilizzare questo attrezzo per rimuovere ed installare l’asta dell’ammortizzatore. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar;. The engine may be damaged if you use the decompression lever while it is running. The decompression lever 1 is located on the left handlebar and is used when starting the engine. The fuel cock has the three positions: OFF:With the lever in this position, fuel will not flow. Always return the lever to this posi- tion when the engine is not running. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. LIGHTS SWITCH The lights switch 1 is located on the handle- bar. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION:. D’autre part, s’assu- gliato come indicato qui di seguito. Inol- schen Kraftstoff verwenden.The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: The carburetor on this motorcycle has a built-in. I gas di Den Motor keinesfalls in geschlos- Ne jamais mettre le moteur en marche scarico sono velenosi, possono provo-.window.parent.OnUploadCompleted(201,"/neu/userfiles/does-jump-manual-work-yahoo-answers(1).xml">http://gesundezellen.com/text/javascript">window.parent.OnUploadCompleted(201,"/neu/userfiles/does-jump-manual-work-yahoo-answers(1).xml Open the hot starter knob (red) and start the engine by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, push in the hot starter knob to close the air passage. Check the idle speed, and check the operation of the controls and the engine stop switch. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float bowl. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached. Nach Jedes Jedes. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page. Prima di usare questo veicolo, controllare quanto segue: ISPEZIONE GENERALE E MANUTENZIONE Elemento Routine. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: Seat Left side cover Refer to ”SEAT FUEL TANK AND SIDE COVERS”. Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be han- dled with special care. Tighten the locknut. CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebar is turned fully both ways. NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: Do not twist the element when squeezing the element. Leaving too much of solvent in the ele- ment may result in poor starting. Replacement steps: Remove the oil filter element cover 1 and oil filter element 2. Check the O-rings 3, if cracked or dam- aged, replace them with a new one. Refer to “PILOT SCREW ADJUSTMENT”. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjust- ment. Do not start the engine when cleaning the exhaust system. 1. Remove: Bolt (spark arrester) 1 2. A brake hose has been loosened or removed. The brake fluid is very low.Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. j. Add brake fluid to the level line on the reservoir. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: Brake pedal height Pedal height adjustment steps: Loosen the locknut 1. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end. Installare la spina delle pastiglie B. Installer le bouchon de goupille de plaquette B. Haltestift-Abdeck- Spina pastiglie: schraube 3 Nm Bouchon de goupille de. Loosen the bleed screw and push the brake caliper piston in. Refer “BRAKE SYSTEM BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: Drive chain 1 NOTE: Remove the drive chain using a drive chain cutter 2. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: Steering stem Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth. Insulator color 2 Normal condition is a medium to light tan color. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become. Direction b Headlight beam is lowered. 3 - 50. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat, fuel tank and left Refer to “SEAT, FUEL TANK AND SIDE COVERS”. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.http://www.amagato.com/images/conair-gs5rc-manual.pdf When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-. Clamp Throttle position sensor lead cou- pler Throttle cable cover Throttle cable. Throttle shaft assembly Push rod link lever assembly Intake joint Pilot air jet Main air jet Cold starter plunger Hot starter plunger (red) Ensemble de l’axe de papillon Ensemble du levier de timonerie de tige de commande Raccord d’admission. REMOVAL POINTS Pilot screw 1. Remove: Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: Hold the carburetor in an upside down position. NOTE: Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. Install: Valve seat Screw (valve seat) 1 Needle valve 2 Float 3 Float pin 4 NOTE: After installing the needle valve to the float, install them to the carburetor. Install: Diaphragm (accelerator pump) 1 Spring 2 O-ring 3 Accelerator pump cover 4 Bolt (accelerator pump cover) 5 NOTE: Install the diaphragm (accelerator pump) with. Accelerator pump timing adjustmet Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. Carburetor Refer to “CARBURETOR”. Camshaft cap Clip Exhaust camshaft Intake camshaft. Checking steps: Turn the crankshaft counterclockwise with a wrench. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. Align the T.D.C. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly. Damage improper valve timing will result.Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER”. Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden. Valve lifter Use special tool. Adjusting pad Refer to “REMOVAL POINTS”. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal. 6. Lapping steps: Apply a coarse lapping compound to the valve face. Free length (valve spring): Intake: 37.81 mm (1.49 in): 35.9 mm (1.41 in) Exhaust: 37.54 mm (1.48 in): 35.7 mm (1.41 in) 2. Combination Valve lifter mark b Cylinder head mark a (color) (color) Bolt (cylinder) Cylinder Piston pin clip Piston pin Use special tool. Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard. CAUTION: Pass the timing chain 3 through the tim- ing chain cavity. Be careful not to damage the timing chain guide 4 during installation. Look washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - 51. Measure at all four points.Reibscheiben Satz blocco il disco conduttore. Apply the engine oil on the push lever shaft. Oil seal Bearing 4 - 58. EC4H4600 Bearing 1. Inspect: Bearing Rotate inner race with a finger. Mesh the impeller shaft gear 3 with primary drive gear 4. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”. When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to “REMOVAL POINTS”. 4 - 73. EC4C3101 Shift guide and shift lever assembly 1. Remove: Bolt (shift guide) Shift guide 1 Shift lever assembly 2 NOTE:. Bolt (left radiator) Refer to “RADIATOR”. Support the machine securely so there is no danger of it falling over. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”. Right engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”. Loosen the nut while applying the rear brake. 2. Remove: Drive sprocket 1 Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. Piston Refer to “CYLINDER AND PISTON” sec- tion. Clutch cable holder Right crankcase Left crankcase Oil strainer. Oil seal Bearing Refer to “REMOVAL POINTS”. Crankcase bearing 1. Remove: Bearing 1 NOTE: Remove the bearing from the crankcase by pressing its inner race. Use the dial gauge and a thickness gauge.Remove assembly carefully. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. Use a socket that matches the outside diam- eter of the race of the bearing. Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube. 6. Install the bearing with seal facing outward. CAUTION: Install the brake hose so that its pipe por- tion a directs as show and lightly touches the projection b on the brake caliper. CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that its bent portion b faces downward. Refer “BRAKE FLUID LEVEL INSPECTION” section in the CHAP- TER 3. Fork spring Drain the fork oil. Dust seal Stopper ring Refer to “REMOVAL POINTS”. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to foreign material. Pertanto si consiglia di affidare gneuse attention.CAUTION: Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can be pulled out from the outer tube. Fork spring free length: 460 mm (18.1 in): 455 mm (17.9 in) EC554502 Inner tube. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: Damper rod 1 To inner tube 2. With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Dans l’ouverture de fourreau. HINWEIS: NOTA: Die Gleitbuchse mit dem Gabeldicht- Premere il metallo di scorrimento nel N.B.: Enfoncer la bague antifriction dans le. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger tight. Decompression lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Light switch. Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1. First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side. First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side. Ball race Refer to “REMOVAL POINTS”. 5 - 48. Le desserrer d’un tour. Lower bearing 1. Remove: Lower bearing 1 Use the floor chisel 2. Install the bearing in the ball races. Spin the bearings by hand. NOTE: Apply the molybdenum disulfide grease on the bearing when installing. Install the bearing by pressing it on the side having the manufacture’s marks or numbers. NOTE: Apply the molybdenum disulfide grease on the bolt.Install: Cap 1 NOTE: Install the right cap with its mark a facing for- ward. Adjuster Only loosening. Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 - 61. Reihen- Demontage-Arbeiten Bauteil. WARNING To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 62. CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted. Apply the lithium soap base grease on the bushing, collars and dust seals. Install the dust seals with their lips facing outward. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions. No good Check entire ignition Repair or replace.No good Check throttle position Throttle posi- Replace. Controllare il collegamento Non funziona dell’intero Riparare o sostituire. In Ordnung Die gesamte Lichtanlage auf Nicht in Ordnung einwandfreie Verbindungen Erneuern. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor. Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor parts may prevent the carburetor from functioning correctly. Bien veiller, lors (Schmutz, Sand, Wasser usw.). Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each. Hard breathing (Gradually) If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat. The front fork setting includes the following three factors: 1. Setting of air spring characteristics Change the fork oil level. WARNING Always adjust each front fork to the same setting. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: Change the rebound damping. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload Change the set length of the spring. Never use one whose overall length is greater than standard. Adjust the rebound damping in 2-click increments or decrements. Adjust the low compression damping in 1-click increments or decrements. Regolare lo smorzamento di espansione in incrementi o decrementi di 2 scatti. Regolare lo smorzamento di compressione bassa in incrementi o decrementi di 1 scatto. This manual should stay with this vehicle if it is sold.Read this manual carefully before operating this vehicle.Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. This model is the culmination of Yama- ha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Off-road use on public lands may also be illegal.The current section title “1”. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque. Coolant drain bolt 4. Throttle grip 15. Rear brake pedal 5. Start switch 16. Air filter 6. Radiator cap 17. Do not use any used parts, because these may not be genuine though they have similar ap- pearances or because the quality may be changed by aging. All gasket surfaces, oil seal lips, and O-rings must be cleaned so that there may be no dust on them. 2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips before installation. NOTICE Be sure to connect the battery leads to the correct battery terminals. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and tool number used for the special tool differ by country, so two types are provided. Mityvac cooling system tester YU-24460-A Radiator cap tester adapter This tool is used to check the 90890-01352 radiator and the radiator cap. YM-04019 YM-04019 Spacer (crankshaft installer) This tool is used to install the 90890-04081 crankshaft. YM-A8998 Valve spring compressor at- This tool is used to discon- tachment nect or connect the valve and 90890-04108 the valve spring. If this occurs, have a Yamaha disengage the clutch, and release the lever to dealer check the vehicle. The display. If the timer is not in operation, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset tripmeter A (TRIP A) display by push- ing the “RST”. A long push on the button will fast-forward the change. Change can be made any time while timer measurement is or is not being made. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction. NOTICE Before running, do maintenance on the air filter element. Lubricate the drive chain and adjust its ten- Refer to “PRE-OPERATION INSPECTION sion. Be sure to avoid using cloths or sponges which have been in con- tact with strong or abrasive cleaning prod- CARE EAS2GB7059 ucts, solvent or thinner, fuel (gasoline),. WARNING! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached. Route the clutch cable 2. Throttle cable (return) outside the neutral switch lead, AC magneto lead 3. Throttle cable (pull) and starter motor lead. Radiator hose 11. Radiator fan motor relay (blue tape) 11. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain,. Change gasket. CYLINDER Inspect score marks. Inspect and clean Inspect wear. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE EAS2GB7080 ITEM inspect Page. Direction “a” b. Turn the adjuster “2” until the specified free Clutch lever free play is increased. The pads worn up to the indicator “b” grooves mean that the brake pad thickness limit is reached. Brake pad lining thickness (inner) d. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate. To the high tension code “3”. EAS2GB7134 REPLACING THE HEADLIGHT BULB Timing light WARNING 90890-03141 Since the headlight bulb gets extremely hot,. NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. Rebound damping tends to become weak- tual run and the circuit conditions.Standard Position in which the spring is turned in 10 mm (0.39 in) from its free length. Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping.Rebound Turn adjuster counterclock- damping force wise (about 2 clicks) to de- crease damping. EAS2GB7153 REMOVING THE SEAT The fuel tank cap cover and the seat are cou- pled with each other with a plastic band. Refer to “CHECKING THE FRONT WHEEL” WARNING on page 5-5. Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-24. Brake lever Union bolt Copper washers Front brake hose Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm Front brake master cylinder float Front brake master cylinder holder Front brake master cylinder. Brake fluid Refer to “BLEEDING THE BRAKE SYSTEM” on page 3-24. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce-. DOT 4 Refer to “BLEEDING THE BRAKE SYS- TEM”. Clutch switch Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable (pull) Disconnect. Throttle cable (return) Disconnect. Right grip Tube guide Start switch Left grip Handlebar upper holder. If there is any contact with the fuel tank, adjust the handlebar position. If it does not, retighten the master cylinder assembly to be level. Front wheel Refer to “FRONT WHEEL” on page 5-4. Front brake caliper Refer to “FRONT BRAKE” on page 5-13. Brake hose holder Protector Upper bracket pinch bolts. Fit the oil seal clip correctly in the groove in the Distance “a” outer tube. 16 mm (0.63 in) or more Between the damper assembly “1”. Be careful not to dam- age the inner tube. If there is any binding, remove the Apply the lithium-soap-based grease on the steering stem and check the steering bear- bearing and bearing race cover lip. ing. 3. Brake hose holder Refer to “REAR BRAKE”. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. Therefore, keep the drive chain slack within the speci- fied limits. Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Intake valve. Before removing the internal parts of the cylin- b. Check that the valves are properly sealed.Cylinder head Cylinder body Gaskets. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Brake pedal Refer to “ENGINE REMOVAL” on page 6-1. Clutch cable Disconnect. Clutch cover Gasket Clutch spring Pressure plate Push rod 1. Pitting on the clutch housing dogs will cause er- ratic clutch operation.Tighten the bolts in stages and in a crisscross pattern. Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft For installation, reverse the removal proce- dure. Right crankcase cover Refer to “CLUTCH”. Shift cam and shift fork Refer to “TRANSMISSION” on page 6-76. Circlip Oil seals Bearing. Crankcase Refer to “CRANKCASE” on page 6-68. Transmission Refer to “TRANSMISSION” on page 6-76. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure. Crankshaft installer pot 90890-01274 INSTALLING THE BALANCER SHAFT EAS2GB7321 Installing pot. Main axle Drive axle Long shift fork guide bar Short shift fork guide bar Spring Shift cam. Apply compressed air to the rear of the radi- ator. Correct any flattened fins with a thin, flat-head screwdriver. Coolant Refer to “CHANGING THE COOLANT” on page 3-10. Drain. This is because re- sidual pressure in the fuel hose could cause fuel to spurt out when the hose is removed. Affix the protector as shown. 0 mm (0 in) 15 mm (0.59 in) Refer to “FUEL INJECTION SYSTEM” on page 9-28.Replace the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 9-75.Replace the main relay. Refer to “CHECKING THE RE- LAYS” on page 9-72. Replace the neutral switch. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE BULBS Replace the bulb (s). Replace the fuel sender assembly. Refer to “CHECKING THE FUEL SENDER” on page 9-77.Refer to “CHECKING THE FUSES” on page 9-68. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32. b. Check the fault code number displayed on the Yamaha diagnostic tool. c. Identify the faulty system with the fault code number. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231. For information on how to connect and use the Yamaha diagnostic tool, refer to “YAMAHA DIGNO- STIC TOOL OPERATION MANUAL”. 1. Vehicle 2. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor.Fault code No. Item Intake air pressure sensor: open or short circuit detected. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode.