Yamaha MTN1000G 2016 Manuals

Manuals and User Guides for Yamaha MTN1000G 2016. We have 1 Yamaha MTN1000G 2016 manual available for free PDF download: Service Manual

Yamaha MTN1000G 2016 Service Manual

Yamaha MTN1000G 2016 Service Manual (658 pages)

Brand: Yamaha | Category: Motorcycle | Size: 66.78 MB

Table of Contents

Table of Contents

7
- Symbols
  6
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    YCC-T (Yamaha Chip Controlled Throttle)
    11
    
    Outline of the Cruise Control System
    13
    
    OUTLINE of the TCS (Traction Control System)
    20
    
    Multi-Function Display
    23
  - Important Information
    30
    
    Preparation for Removal and Disassembly
    30
    
    Replacement Parts
    30
    
    Gaskets, Oil Seals and O-Rings
    30
    
    Lock Washers/Plates and Cotter Pins
    30
    
    Bearings and Oil Seals
    30
    
    Circlips
    31
    
    Rubber Parts
    31
  - Basic Service Information
    32
    
    Quick Fasteners
    32
    
    Electrical System
    33
  - Special Tools
    37
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  52
- Electrical Specifications
  55
- Tightening Torques
  57
- Lubrication Points and Lubricant Types
  60
  - Engine
    60
  - Chassis
    61
- Lubrication System Chart and Diagrams
  64
  - Engine Oil Lubrication Chart
    64
  - Lubrication Diagrams
    66
- Cooling System Diagrams
  80
- Cable Routing
  84
Periodic Checks and Adjustments

131
- General Maintenance and Lubrication Chart
  133
- Introduction
  133
- Periodic Maintenance
  133
- Periodic Maintenance Chart for the Emission Control System
  133
- Checking the Fuel Line
  136
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  136
- Adjusting the Valve Clearance
  137
- Checking the Spark Plugs
  137
- Checking the Crankcase Breather Hose
  141
- Checking the Engine Idling Speed
  141
- Synchronizing the Throttle Bodies
  142
- Checking the Exhaust System
  143
- Checking the Throttle Body Joints
  143
- Adjusting the Exhaust Gas Volume
  144
- Checking the Air Induction System
  144
- Checking the Canister
  144
- Replacing the Air Filter Element
  144
- Adjusting the Clutch Lever Free Play
  145
- Checking the Brake Fluid Level
  146
- Checking the Brake Operation
  146
- Adjusting the Front Disc Brake
  147
- Adjusting the Rear Disc Brake
  147
- Checking the Front Brake Pads
  147
- Bleeding the Hydraulic Brake System (Abs)
  148
- Checking the Front Brake Hoses
  148
- Checking the Rear Brake Hose
  148
- Checking the Rear Brake Pads
  148
- Checking the Tires
  149
- Checking the Wheels
  149
- Checking the Swingarm Operation
  151
- Checking the Wheel Bearings
  151
- Drive Chain Slack
  151
- Lubricating the Swingarm Pivot
  151
- Checking and Adjusting the Steering Head
  152
- Lubricating the Drive Chain
  152
- Checking the Chassis Fasteners
  153
- Checking the Steering Damper
  153
- Lubricating the Brake Lever
  153
- Lubricating the Steering Head
  153
- Adjusting the Front Fork Legs
  154
- Checking the Front Fork
  154
- Checking the Sidestand
  154
- Checking the Sidestand Switch
  154
- Lubricating the Clutch Lever
  154
- Lubricating the Pedal
  154
- Lubricating the Sidestand
  154
- Adjusting the Rear Shock Absorber Assembly
  156
- Checking the Rear Shock Absorber Assembly
  156
- Changing the Engine Oil
  158
- Checking the Connecting Arm and Relay Arm
  158
- Checking the Engine Oil Level
  158
- Engine
  159
  - Measuring the Engine Oil Pressure
    159
  - Checking the Coolant Level
    161
  - Checking the Cooling System
    161
  - Changing the Coolant
    161
- Cooling System
  163
  - Adjusting the Exup Cables
    164
  - Checking the Front Brake Light Switch
    165
  - Adjusting the Rear Brake Light Switch
    165
  - Checking and Lubricating the Cables
    165
  - Checking the Throttle Grip
    165
  - Checking and Charging the Battery
    167
  - Checking the Fuses
    167
  - Adjusting the Headlight Beams
    167
Engine

281
- Engine Inspection
  
  284
  - Measure the Compression Pressure
    284
- Engine Removal
  
  286
  - Removing the Engine
    290
  - Installing the Engine
    290
  - Installing the Exhaust Pipe and Muffler
    291
- Camshafts
  
  292
- Cylinder Head
  
  306
  - Removing the Cylinder Head
    307
  - Installing the Cylinder Head
    307
- Valves and Valve Springs
  
  311
  - Removing the Valves
    311
  - Checking the Valves and Valve Guides
    311
  - Checking the Valve Seats
    313
  - Checking the Valve Springs
    314
  - Installing the Valves
    315
- Generator
  
  317
  - Removing the Generator
    318
  - Installing the Generator
    318
- Starter Clutch
  
  320
  - Removing the Starter Clutch
    321
  - Checking the Starter Clutch
    321
  - Installing the Starter Clutch
    321
- Electric Starter
  
  323
  - Checking the Starter Motor
    325
  - Assembling the Starter Motor
    326
- Oil Pump
  
  330
  - Removing the Oil Pan
    330
  - Checking the Sprocket and Chain
    330
  - Checking the Oil Pump
    330
  - Checking the Relief Valve
    331
  - Checking the Oil Delivery Pipes
    331
  - Checking the Oil Strainer
    331
  - Assembling the Oil Pump
    331
  - Installing the Oil Pump
    332
  - Installing the Oil Pan
    333
- Clutch
  
  334
  - Removing the Clutch
    337
  - Checking the Friction Plates
    338
  - Checking the Clutch Plates
    338
  - Checking the Clutch Springs
    339
  - Checking the Clutch Housing
    339
  - Checking the Clutch Boss
    339
  - Checking the Pressure Plate
    339
  - Checking the Primary Drive Gear
    340
  - Checking the Pull Lever Shaft and Pull Rod
    340
  - Installing the Clutch
    340
- Shift Shaft
  
  343
  - Checking the Shift Shaft
    344
  - Checking the Stopper Lever
    344
  - Installing the Shift Shaft
    344
- Crankcase
  
  345
  - Disassembling the Crankcase
    348
  - Checking the Crankcase
    348
  - Assembling the Crankcase
    348
  - Installing the Oil Pressure Switch
    350
  - Installing the Gear Position Sensor
    351
- Connecting Rods and Pistons
  
  353
  - Removing the Connecting Rods and Pistons
    353
  - Checking the Cylinder and Piston
    353
  - Checking the Piston Rings
    354
  - Checking the Piston Pin
    355
  - Checking the Connecting Rods
    356
  - Installing the Connecting Rod and Piston
    358
- Crankshaft and Balancer Shaft
  
  363
  - Removing the Crankshaft and Balancer Shaft
    364
  - Checking the Oil Nozzles
    364
  - Checking the Crankshaft
    364
  - Checking the Balancer Shaft
    366
  - Installing the Crankshaft
    368
  - Installing the Thrust Bearing
    368
  - Installing the Balancer Assembly
    369
- Transmission
  
  370
  - Removing the Transmission
    374
  - Checking the Shift Forks
    374
  - Checking the Shift Drum Assembly
    375
  - Checking the Transmission
    375
  - Assembling the Main Axle and Drive Axle
    375
  - Installing the Transmission
    376
Cooling System

379
- Cooling System
  
  380
  - Radiator
    380
  - Removing the Radiator
    381
  - Checking the Radiator
    381
  - Installing the Radiator
    382
  - Oil Cooler
    383
- Radiator
  
  380
- Checking the Oil Cooler
  
  384
  - Installing the Oil Cooler
    384
- Thermostat
  
  385
  - Removing the Thermostat Assembly
    386
  - Checking the Thermostat
    386
  - Assembling the Thermostat Assembly
    386
  - Installing the Thermostat Assembly
    386
- Water Pump
  
  388
  - Disassembling the Water Pump
    390
  - Checking the Water Pump
    390
  - Assembling the Water Pump
    390
  - Installing the Water Pump
    391
Fuel System

393
- Fuel Tank
  
  396
  - Removing the Fuel Tank
    396
    
    Removing the Fuel Pump
    396
    
    Checking the Fuel Pump Body
    396
    
    Checking the Fuel Pump Operation
    396
    
    Installing the Fuel Pump
    397
    
    Installing the Fuel Tank
    397
- Throttle Bodies
  
  398
  - Checking the Injectors (before Removing)
    401
    
    Removing the Fuel Hose (Fuel Rail Side)
    401
    
    Removing the Injectors
    401
    
    Checking the Injectors
    401
    
    Checking and Cleaning the Throttle Bodies
    401
    
    Replacing the Throttle Bodies
    403
    
    Installing the Injectors
    403
    
    Checking the Injector Pressure
    404
    
    Checking the Fuel Pressure
    404
    
    Installing the Fuel Hose (Fuel Rail Side)
    405
    
    Adjusting the Throttle Position Sensor
    405
    
    Adjusting the Accelerator Position Sensor
    406
- Air Induction System
  
  408
  - Checking the Air Induction System
    412
  - Installing the Air Induction System
    413
Electrical System

415
- General Information
  416
- Ignition System
  
  418
  - Circuit Diagram
    418
  - Engine Stopping Due to Sidestand Operation
    420
  - Troubleshooting
    421
- Electric Starting System
  
  424
  - Circuit Diagram
    424
  - Starting Circuit Cut-Off System Operation
    426
  - Troubleshooting
    427
- Charging System
  
  430
  - Circuit Diagram
    430
  - Troubleshooting
    432
- Lighting System
  
  434
  - Circuit Diagram
    434
  - Troubleshooting
    436
- Signaling System
  
  438
  - Circuit Diagram
    438
  - Troubleshooting
    440
- Cooling System
  
  446
  - Circuit Diagram
    446
  - Troubleshooting
    448
- Fuel Injection System
  
  450
  - Circuit Diagram
    450
  - Ecu Self-Diagnostic Function
    452
  - Troubleshooting Method
    452
  - Yamaha Diagnostic Tool
    453
  - Troubleshooting Details (Fault Code)
    454
  - Specifications
    480
  - Troubleshooting
    627

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