d unfit for use.

Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and sig-

es in specifications or procedures will be forwarded to all authorized Yamaha dealers and

future editions of this manual where applicable.

specifications are subject to change without notice.

MANUAL INFORMATION

mportant information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal inju-

ry hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

G

titles “2” appear in smaller print than the section title.

tify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

disassembly section.

” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

.

indicate parts to be lubricated or replaced.

MBOLS”.

tion chart “6” accompanies the exploded diagram, providing the order of jobs, names of

in jobs, etc.

uiring more information (such as special tools and technical data) are described sequen-

CLUTCH

EAS30346

REMOVING THE CLUTCH

1. Straighten the lock washer tab.

2. Loosen:

• Clutch boss nut “1”

TIP

While holding the clutch boss “2” with the univer-

sal clutch holder “3”, loosen the clutch boss nut.

EAS30348

CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-

tion plates.

1. Check:

• Friction plate

Damage/wear

Replace the friction plates

as a set.

2. Measure:

• Friction plate thickness

Out of specification

Replace the friction

plates as a set.

TIP

Measure the friction plate at four places.

EAS30349

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the

clutch plates.

1. Check:

• Clutch plate

Damage

Replace the clutch plates as a

set.

2. Measure:

• Clutch plate warpage

(with a surface plate and thickness gauge “1”)

Out of specification

Replace the clutch

plates as a set.

EAS30351

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the

clutch springs.

1. Check:

• Clutch spring

Damage

Replace the clutch springs as a

set.

2. Measure:

• Clutch spring free length “a”

Out of specification

Replace the clutch

springs as a set.

Clutch hub holder

YSST-733A

Friction plate 1, 2, 3 thickness

2.92–3.08 mm (0.115–0.121 in)

Wear limit

2.82 mm (0.111 in)

Feeler gauge set

Clutch plate thickness 1

2.18–2.42 mm (0.085–0.095 in)

Warpage limit

0.10 mm (0.0039 in)

Clutch plate thickness 2

2.20–2.40 mm (0.086–0.094 in)

Warpage limit

0.10 mm (0.0039 in)

CLUTCH

he clutch cover

Job/Parts to remove

Q’ty

Remarks

Engine oil

Drain.

Refer to “CHANGING THE ENGINE OIL” on

page 3-9.

Lower side cowling (right)

Refer to “GENERAL CHASSIS” on page

4-1.

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2

nip

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w

o

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1

la

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s li

O

1

S

New

7 New

New

LS

4

6

6

5

2

(6)

(4)

3

E

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R.

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R.

1

7

2

Serviceable with engine mounted

Gear oil

illing fluid

Molybdenum disulfide oil

ubricant

Brake fluid

Special tool

Wheel bearing grease

Tightening torque

Lithium-soap-based grease

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Apply locking agent (LOCTITE®).

Engine oil

Replace the part with a new one.

Silicone fluid

G

M

BF

B

LS

M

S

LT

New

O

O

1

ECIFICATIONS

2

RIODIC CHECKS AND

JUSTMENTS

3

ASSIS

4

GINE

5

ECTRICAL SYSTEM

6

1

ATURES..................................................................................................... 1-2

OUTLINE OF THE ABS............................................................................ 1-2

ABS COMPONENT FUNCTIONS ............................................................ 1-6

ABS OPERATION .................................................................................. 1-11

ABS WARNING LIGHT AND OPERATION............................................ 1-14

INDICATOR LIGHTS AND WARNING LIGHTS..................................... 1-16

ABS WARNING LIGHT .......................................................................... 1-16

1-1

IAL NUMBER

rial number “1” is stamped into the

1-2

.

ulic unit assembly, which is the main component of the ABS, is centrally located on the

ncrease mass centralization.

coupler

rol unit fuse

noid fuse

or fuse

ning light

eel sensor rotor

eel sensor

unit assembly

el sensor rotor

10.Rear wheel sensor

1-3

d:

speed of the front and rear wheels.

ed:

of the chassis.

akes are applied, wheel speed and chassis speed are reduced. However, the chassis

ard by its inertia even though the wheel speed is reduced.

pplied by braking to reduce the wheel speed.

hat occurs when the rotation of one or both of the wheels has stopped, but the vehicle

travel.

n the tires which supports the vehicle when cornering.

akes are applied, slipping occurs between the tires and the road surface. This causes a

etween the wheel speed and the chassis speed.

he value that shows the rate of wheel slippage and is defined by the following formula.

Chassis speed – Wheel speed)/Chassis speed  100 (%)

s no slipping between the wheel and the road surface. The chassis speed is equal to the

d.

wheel speed is “0”, but the chassis is moving (i.e., wheel lock).

and vehicle stability

ke pressure is increased, wheel speed is reduced. Slipping occurs between the tire and

ce and brake force is generated. The limit of this brake force is determined by the friction

n the tire and the road surface and is closely related to wheel slippage. Wheel slippage is

y the slip ratio.

also closely related to wheel slippage. See figure “A”. If the brakes are applied while keep-

slip ratio, it is possible to obtain the maximum brake force without losing much side force.

ll use of the tires’ capabilities even on slippery road surfaces or less slippery road surfac-

“B”.

b

c

d

(%)

a

e

f

g

B

d

(%)

rce between the tire and road

ce

e

e. Less slippery road surface

f.

Controlling zone

g. Slippery road surface

1-4

the wheel has a tendency to lock.

rge and the wheel has a tendency to lock (point “A” in the following figure), the ABS ECU

ydraulic pressure in the brake caliper. Once the ABS ECU determines that the tendency

o lock has diminished after the hydraulic pressure is reduced, it increases the hydraulic

nt “B” in the following figure). The hydraulic pressure is initially increased quickly, and then

gradually.

on and vehicle control

rts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the

. To make the rider aware of this condition, the ABS has been designed to generate a

pulsating action in the brake lever and brake pedal independently.

S is activated, a pulsating action may be felt at the brake lever or brake pedal, but this

ate a malfunction.

e side force on a tire, the less traction there is available for braking. This is true whether

equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-

side force, which ABS cannot prevent, could cause the tire to slip sideways.

d

d

e

d

e

A

A

B

B

A

A

B

B

A

A

B

B

a

e

peed

eed

ce

d. Depressurizing phase

e. Pressurizing phase

1-5

p

y

y

g

y

p

ere is a tendency of the wheel to lock on a slippery road surface, due to engine braking,

not be able to prevent the wheel from locking.

G

ntrols only the tendency of the wheel to lock caused by applying the brakes. The

prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine

n if the ABS is operating.

BS features

ABS (anti-lock brake system) has been developed with the most advanced electronic

trol is processed with good response under various vehicle travel conditions.

includes a highly developed self-diagnosis function. The ABS detects any problem con-

ws normal braking even if the ABS is not operating properly.

curs, the ABS warning light on the meter assembly comes on.

es the fault codes in the memory of the ABS ECU for easy problem identification and trou-

(%)

rce between the tire and road

ce

c. Side force

d. Slip ratio

1-6

NENT FUNCTIONS

rs and wheel sensor rotors

s “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.

ensor is composed of a permanent magnet and a hall IC. The sensor rotors “2” rotate with

he sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the

otates, the hall element in the hall IC installed in the wheel sensor generates pulses. The

cy, which is proportional to the wheel speed, is converted into a wave in the hall IC so that

ut.

U calculates the wheel rotation speed by detecting the pulse frequency.

4

4

7

7

5

6

6

8

9

9

10

11

12

13

14

ke master cylinder

unit assembly

ke master cylinder

noid valve

or

pump

enoid valve

U

9. Buffer chamber

10.Rear brake caliper

11.Rear wheel sensor

12.ABS warning light

13.Front brake caliper

14.Front wheel sensor