Disassembling the water pump

14. Remove:

 

• water pump seal 1

 

NOTE:

Remove the water pump seal from the outside of the water pump housing.

2 Water pump housing

 

 

14. Remove:

 

• oil seal 1

 

(with a thin, flat-head screwdriver)

NOTE:

Remove the oil seal from the outside of the water pump housing.

 

 

• Remove:

 

bearing 1

NOTE:

Remove the bearing from inside of the water pump housing.

 

• Remove:

 

rubber damper holder 1

 

rubber damper 2

 

(from the impeller, with a thin, flat-head screwdriver)

NOTE:

Do not scratch the impeller shaft.

 

 

6 - 12

WATER PUMP ^COOL

 

EAS00474

CHECKING THE WATER PUMP

Й Check:

 

water pump housing cover 1

 

water pump housing 2

 

impeller shaft 3

 

water pump seal 4

 

oil seal 5

 

rubber damper

 

rubber damper holder Cracks/damage/wear → Replace.

Й Check:

 

bearing

 

Rough movement → Replace.

 

EAS00475

ASSEMBLING THE WATER PUMP

 

К Install:

 

oil seal 1 New

 

(to the water pump housing)

^Л 1 New

Installed depth of oil seal a

Mm (0.45 in)

 

NOTE:

П Install the oil seal with a socket that matches its outside diameter.

 

П Before installing the oil seal, apply tap water or coolant onto its outer surface.

 

 

Т Install:

 

bearing 1

 

6 - 13

WATER PUMP ^COOL

 

У Install:

 

water pump seal 1 New

CAUTION:

Never apply oil or grease onto the water pump seal surface.

NOTE:

Ф Install the water pump seal with the special tools.

 

Ф Before installing the water pump seal, apply Yamaha bond No.1215 or Sealant (Quick Gasket^®) 2 to the water pump housing 3.

Mechanical seal installer 90890-04078, YM-33221-A 4

Middle driven shaft bearing driver 90890-04058, YM-04058 5

 

Yamaha bond No.1215 90890-85505

 

Sealant (Quick Gasket^®) ACC-11001-05-01

 

И Push down

 

 

4. Install:

• rubber damper 1 New

 

• rubber damper holder 2 New

 

NOTE:

Before installing the rubber damper, apply tap water or coolant onto its outer surface.

 

6 - 14

WATER PUMP ^COOL

 

Х Measure:

 

tilt

 

Out of specification → Repeat steps (3) and

 

(4).

CAUTION:

Make sure that the rubber damper and rub-ber damper holder are flush with the impel-ler.

 

Maximum impeller shaft tilt 0.15 mm (0.006 in)

 

Ч Straightedge

 

Ч Impeller

 

 

a

 

 

b

 

INSTALLING THE WATER PUMP

 

Ш Install:

 

water pump assembly

 

T.R.	10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Align the projection a at the oil pump shaft and water pump shaft groove b.

LS

2. Fill:

 

• cooling system

 

(with the specified amount of the recom-mended coolant)

 

Refer to “CHANGING THE COOLANT” in chapter 3.

 

3. Check:

 

• cooling system

 

Leaks → Repair or replace any faulty part. 4. Measure:

 

• radiator cap opening pressure

 

Below the specified pressure → Replace the radiator cap.

 

Refer to “CHECKING THE RADIATOR”.

 

6 - 15

 

FI ₇

		FI
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................	7-1
WIRING DIAGRAM...................................................................................	7-2
ECU (engine) SELF-DIAGNOSTIC FUNCTION........................................	7-3
ALTERNATE INSTRUCTIONS OPERATION CONTROL
(FAIL-SAFE ACTION)..............................................................................	7-4
FAIL-SAFE ACTION TABLE.....................................................................	7-4
TROUBLESHOOTING CHART.................................................................	7-6
DIAGNOSTIC MODE................................................................................	7-7
TROUBLESHOOTING DETAILS............................................................	7-12
THROTTLE BODY.........................................................................................	7-23
CHECKING THE FUEL INJECTORS......................................................	7-27
CHECKING THE THROTTLE BODY......................................................	7-27
CHECKING THE FUEL PUMP OPERATION..........................................	7-27
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR................................................................................................	7-29

FI

	FUEL INJECTION SYSTEM			FI
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 Ignition coil	9 Throttle position sensor	G Crankshaft position sensor
2 Air filter case	0 Fuel injector	H Coolant temperature sensor
3 Intake air temperature sensor	A Fuel tank	I Spark plug
4 Fuel injection system relay	B Fuel delivery hose
5 Lean angle cut-off switch	C Fuel pump
6 Engine trouble warning light	D Battery
7 ECU (engine)	E Catalyst
8 Intake air pressure sensor	F O2 sensor

 

 

					A	B C
				D
	I	H	G	F	E
				7 - 1

 

 

7 - 2

 

jectorjector

е

n

oL

olant

L/W Y/L Y/G Gy/G W B/Y B/W Y/B L

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U

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TURN SIGNAL

B

B

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WIRE HARNESS

SUB-WIRE HARNESS 1

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SUB-WIRE HARNESS 2

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i

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f

l

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Br/W

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h

Br/Y

Br/Y

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L

L

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Br Ch Dg

Dg Ch B/Y

m

n

o

p

1 Crankshaft position sensor

B

B

U Ignition coil

L

~G/L

R/G Y/L

G Lg

L

YDg Ch

d

PASS

NR

4 Main switch

B

B

L

L

з

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P Br/W

Br/W P

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NL

VB Spark plugL

(BLUE)

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9ChDg Electrical fuel injection fuse

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Ј § • ¶

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†

ў

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d

L

L

sensor

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F Battery

Y Fuel i

#1

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KBr/GStarter circuit cut-off relay 1

[ Intake air pressure sensor

Y

B

Y

G

G

B

Br/G

y

Br/G

Br/G

BsystemB

relay

\ O

sensor

{ | z L/R

L Fuel injection

L/R E L/R L/R

z

x

w

s t u u v

Y L

L/R G/Y

Br/G

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Br/G

B

Ch Dg

Dg Ch

L/R

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Br

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MB Fuel pump

] Throttle position sensor

B C

B

B

B

P Engine s switch

B

G

G

B

_ Lean angle cut-off switch

B

B

B

S Sidestand switch

a Speed sensor

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