Yamaha CZD300-AH Manuals

Manuals and User Guides for Yamaha CZD300-AH. We have 1 Yamaha CZD300-AH manual available for free PDF download: Service Manual

Yamaha CZD300-AH Service Manual

Yamaha CZD300-AH Service Manual (462 pages)

Brand: Yamaha | Category: Motorcycle | Size: 41.88 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Multi-Function Display
  11
- Special Tools
  19
Specifications

23
- General Specifications
  24
- Engine Specifications
  25
- Chassis Specifications
  30
- Electrical Specifications
  32
- Engine Tightening Torques
  34
- Tightening Torques
  34
- Chassis Tightening Torques
  35
- Cable Routing
  36
Periodic Checks and Adjustments

69
Chassis

97
- General Chassis (1)
  101
- Installing the Battery Band
  101
- Installing the Battery Cover Assembly
  101
- Removing the Battery Cover Assembly
  101
- Adjusting the Windshield Height
  102
- Assembling the Battery Cover Assembly
  102
- Disassembling the Battery Cover Assembly
  102
- General Chassis (2)
  103
- Assembling the Front Cowling Assemblies
  104
- Disassembling the Front Cowling Assemblies
  104
- Installing the Front Cowling Assemblies
  104
- Removing the Front Cowling Assemblies
  104
- General Chassis (3)
  105
- Installing the Meter Assembly Panel Molding
  108
- Removing the Meter Assembly Panel Molding
  108
- General Chassis (4)
  109
- Installing the Lower Center Cover
  110
- Installing the Upper Side Covers
  110
- Removing the Lower Center Cover
  110
- Removing the Upper Side Covers
  110
- Installing the Lower Side Covers
  111
- Removing the Lower Side Covers
  111
- General Chassis (5)
  112
- Assembling the Footrest Board Assemblies
  114
- Disassembling the Footrest Board Assemblies
  114
- Installing the Radiator Cover
  114
- General Chassis (6)
  115
- Installing the Fuel Tank Cap Lid Cover
  118
- Installing the Upper Center Cover
  118
- Removing the Fuel Tank Cap Lid Cover
  118
- Removing the Upper Center Cover
  118
- General Chassis (7)
  119
- Installing the Seat Damper
  121
- General Chassis (8)
  122
- Installing the Rear Center Cover
  124
- Removing the Rear Center Cover
  124
- Removing the Rear Upper Cowlings
  124
- Installing the Rear Upper Cowlings
  125
- Front Wheel
  126
- Checking the Front Wheel
  128
- Disassembling the Front Wheel
  128
- Removing the Front Wheel
  128
- Assembling the Front Wheel
  129
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  129
- Adjusting the Front Wheel Static Balance
  130
- Installing the Front Wheel (Front Brake Disc)
  130
- Rear Wheel
  133
- Adjusting the Rear Wheel Static Balance
  134
- Checking the Rear Wheel
  134
- Installing the Rear Wheel Sensor
  134
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  134
- Removing the Rear Wheel (Disc)
  134
- Installing the Rear Wheel (Rear Brake Disc)
  135
- Front Brake
  139
- Checking the Front Brake Disc
  143
- Introduction
  143
- Replacing the Front Brake Pads
  144
- Disassembling the Front Brake Caliper
  145
- Removing the Front Brake Caliper
  145
- Assembling the Front Brake Caliper
  146
- Checking the Front Brake Caliper
  146
- Installing the Front Brake Caliper
  146
- Removing the Front Brake Master Cylinder
  147
- Assembling the Front Brake Master Cylinder
  148
- Checking the Front Brake Master Cylinder
  148
- Installing the Front Brake Master Cylinder
  148
- Rear Brake
  150
- Checking the Rear Brake Disc
  156
- Introduction
  156
- Replacing the Rear Brake Pads
  156
- Removing the Rear Brake Caliper
  157
- Assembling the Rear Brake Caliper
  158
- Checking the Rear Brake Caliper
  158
- Disassembling the Rear Brake Caliper
  158
- Installing the Rear Brake Caliper
  159
- Assembling the Rear Brake Master Cylinder
  160
- Checking the Rear Brake Master Cylinder
  160
- Installing the Rear Brake Master Cylinder
  160
- Removing the Rear Brake Master Cylinder
  160
- Abs (Anti-Lock Brake System)
  164
- Checking the Hydraulic Unit Assembly
  164
- Installing the Hydraulic Unit Assembly
  164
- Removing the Hydraulic Unit Assembly
  164
- Hydraulic Unit Operation Tests
  166
- Checking the Abs Warning Light
  169
- Handlebar
  170
- Adjusting the Handlebar Position
  173
- Removing the Handlebar
  173
- Removing the Upper Handlebar Cover
  173
- Checking the Handlebar
  174
- Installing the Handlebar
  174
- Installing the Upper Handlebar Cover
  176
- Front Fork
  177
- Disassembling the Front Fork Legs
  181
- Removing the Front Fork Legs
  181
- Assembling the Front Fork Legs
  182
- Checking the Front Fork Legs
  182
- Installing the Front Fork Legs
  185
- Steering Head
  186
- Checking the Steering Head
  188
- Installing the Steering Head
  188
- Removing the Lower Bracket
  188
- Rear Shock Absorber Assemblies and Swingarm
  190
- Checking the Rear Shock Absorber Assembly
  191
- Checking the Swingarm
  191
- Installing the Swingarm
  191
- Removing the Rear Shock Absorber Assemblies
  191
- Removing the Swingarm
  191
Engine

193
- Engine Oil Lubrication Chart
  196
- Lubrication System Chart and Diagrams
  196
- Lubrication Diagrams
  197
- Engine Inspection
  200
- Measuring the Compression Pressure
  200
- Checking the Breather Hoses
  201
- Engine Removal
  202
- Connecting the Leads
  206
- Installing the Engine
  206
- Installing the Exhaust Pipe and Muffler
  207
- Cylinder Head
  208
- Checking the Cylinder Head
  212
- Removing the Cylinder Head
  212
- Checking the Camshaft Sprocket
  213
- Checking the Timing Chain Tensioner
  213
- Installing the Cylinder Head
  213
- Camshaft
  217
- Checking the Camshaft Assembly
  218
- Checking the Rocker Arms and Rocker Arm Shafts
  218
- Removing the Camshaft
  218
- Installing the Camshaft
  219
- Valves and Valve Springs
  221
- Checking the Valves and Valve Guides
  222
- Removing the Valves
  222
- Checking the Valve Seats
  224
- Checking the Valve Springs
  225
- Installing the Valves
  225
- Cylinder and Piston
  227
- Checking the Cylinder and Piston
  228
- Removing the Piston
  228
- Checking the Piston Rings
  229
- Checking the Piston Pin
  230
- Checking the Timing Chain Guide (Exhaust Side)
  230
- Installing the Piston and Cylinder
  230
- V-Belt Automatic Transmission
  232
- Disassembling the Secondary Sheave
  235
- Removing the Primary Fixed Sheave
  235
- Removing the Secondary Sheave
  235
- Checking the Clutch Housing
  236
- Checking the Clutch Shoes
  236
- Checking the Primary Sheave
  236
- Checking the V-Belt
  236
- Assembling the Secondary Sheave
  237
- Checking the Primary Sheave Sliders
  237
- Checking the Primary Sheave Weights
  237
- Checking the Secondary Sheave
  237
- Assembling the Primary Fixed Sheave
  238
- Installing the Primary Sheave, V-Belt and Secondary Sheave
  239
- Generator and Starter Clutch
  241
- Checking the Starter Clutch
  244
- Removing the Generator
  244
- Removing the Starter Clutch
  244
- Installing the Generator
  245
- Installing the Starter Clutch
  245
- Electric Starter
  247
- Checking the Starter Motor
  249
- Assembling the Starter Motor
  250
- Installing the Starter Motor
  250
- Oil Pump
  251
- Assembling the Oil Pump
  254
- Checking the Oil Pump
  254
- Checking the Oil Pump Drive Chain
  254
- Checking the Oil Strainer
  254
- Installing the Oil Pump
  255
- Crankcase
  256
- Assembling the Crankcase
  258
- Checking the Crankcase
  258
- Checking the Oil Strainer
  258
- Checking the Relief Valve
  258
- Checking the Timing Chain and Timing Chain Guide
  258
- Disassembling the Crankcase
  258
- Crankshaft
  260
- Checking the Crankshaft and Connecting Rod
  262
- Removing the Crankshaft Journal Bearings
  262
- Checking the Balancer Shaft Assembly
  265
- Installing the Connecting Rod
  265
- Installing the Crankshaft Journal Bearings
  266
- Installing the Crankshaft Assembly and Balancer Shaft Assembly
  267
- Transmission
  268
- Checking the Transmission
  270
- Installing the Transmission
  270
Cooling System

271
- Cooling System Diagrams
  272
- Radiator
  273
- Checking the Radiator
  275
- Installing the Radiator
  275
- Thermostat
  277
- Checking the Thermostat Assembly
  278
- Installing the Thermostat Assembly
  278
- Water Pump
  279
- Assembling the Water Pump
  281
- Checking the Water Pump
  281
- Disassembling the Water Pump
  281
- Installing the Generator Cover
  281
Fuel System

283
- Fuel Tank
  284
- Checking the Fuel Filter
  288
- Checking the Fuel Pump Body
  288
- Checking the Rollover Valve
  288
- Removing the Fuel Filter
  288
- Removing the Fuel Pump
  288
- Removing the Fuel Tank
  288
- Installing the Fuel Filter
  289
- Installing the Fuel Pump
  289
- Installing the Fuel Tank
  289
- Checking the Fuel Pressure
  290
- Fuel Injector
  291
- Checking the Fuel Injector
  292
- Installing the Fuel Hose
  292
- Installing the Fuel Injector
  292
- Removing the Fuel Hose
  292
- Air Filter Case
  294
- Installing the Air Filter Case
  295
- Throttle Body
  296
- Checking the Throttle Body
  298
- Cleaning the Isc (Idle Speed Control) Unit and Throttle Body
  298
- Removing the Throttle Body
  298
- Installing the Throttle Body
  301
- Replacing the Throttle Body
  301
Electrical System

303
- Circuit Diagram
  306
- Ignition System
  306
- Troubleshooting
  308
- Circuit Diagram
  310
- Electric Starting System
  310
- Starting Circuit Cut-Off System Operation
  312
- Troubleshooting
  313
- Charging System
  316
- Circuit Diagram
  316
- Troubleshooting
  318
- Circuit Diagram
  320
- Lighting System
  320
- Troubleshooting
  322
- Circuit Diagram
  324
- Signaling System
  324
- Troubleshooting
  326
- Circuit Diagram
  332
- Cooling System
  332
- Troubleshooting
  334
- Circuit Diagram
  336
- Fuel Injection System
  336
- Ecu Self-Diagnostic Function
  338
- Troubleshooting Method
  338
- Troubleshooting Details
  339
- Yamaha Diagnostic Tool
  339
- Troubleshooting
  445
- Self-Diagnostic Function and Diagnostic Code Table
  446
- Self-Diagnostic Function Table
  446
- Diagnostic Code: Sensor Operation Table
  453
- Diagnostic Code: Actuator Operation Table
  454
- Event Code Table
  456

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