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Yamaha 2002 TDM900, Service Manual

The Yamaha 2002 TDM900 Service Manual is a comprehensive guide for maintaining and repairing your motorcycle. This manual is available for download absolutely free from manualshive.com, ensuring easy access to high-quality instructions and insights. Enhance your TDM900 ownership experience with this reliable resource at your fingertips.

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7-8

FUEL INJECTION SYSTEM

FI

Fault

Code No.

Symptom

Probable cause of malfunction

Diagnostic

monitoring code No.

33

Open circuit is detected in the
primary wire of the ignition coil
(#1).

S

Open or short circuit in wiring harness.

S

Malfunction in ignition coil.

S

Malfunction in ECU.

S

Malfunction in a component of ignition cutoff
circuit system.

30

34

Open circuit is detected in the
primary wire of the ignition coil
(#2).

S

Open or short circuit in wiring harness.

S

Malfunction in ignition coil.

S

Malfunction in ECU.

S

Malfunction in a component of ignition cutoff 
circuit system.

31

41

Lean angle cut-off switch-open or
short circuit detected.

S

Open or short circuit in wiring harness.

S

Defective lean angle cut-off switch.

S

Malfunction in ECU.

08

42

No normal signals are received
from the speed sensor; or, an open
or short circuit is detected in the
neutral switch.

S

Open or short circuit in wiring harness.

S

Defective speed sensor.

S

Malfunction in vehicle speed sensor detected
unit.

07

42

S

Defective neutral switch.

S

Malfunction in the engine side of the neutral
switch.

S

Malfunction in ECU.

21

43

The ECU is unable to monitor the
battery voltage (an open circuit in
the monitor line to the ECU).

S

Open circuit in wiring harness.

S

Malfunction in ECU.

—

44

An error is detected while reading
or writing on EEPROM.

S

Malfunction in ECU. (The CO adjustment
value is not properly written on or read from
the internal memory).

60

50

Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.

S

Malfunction in ECU. (The program and data
are not properly written on or read from the
internal memory.)

—

Er-1

No signals are received from the
ECU.

S

Open or short circuit in communication line.

S

Malfunction in meter unit.

S

Malfunction in ECU.

—

Er-2

No signals are received from the
ECU within the specified duration.

S

Open or short circuit in communication line.

S

Malfunction in meter unit.

S

Malfunction in ECU.

—

Er-3

Data from the ECU cannot be
received correctly.

S

Open or short circuit in communication line.

S

Malfunction in meter unit.

S

Malfunction in ECU.

—

Er-4

Non-registered data has been
received from the meter.

S

Open or short circuit in communication line.

S

Malfunction in meter unit.

S

Malfunction in ECU.

—

Summary of Contents for 2002 TDM900

Page 1: ......

Page 2: ......

Page 3: ...00 P 2002 SERVICE MANUAL 2001 by Yamaha Motor Co Ltd First edition November 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...mprove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 5: ...he top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number i...

Page 6: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 7: ...FICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 FI 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS ...

Page 8: ......

Page 9: ......

Page 10: ...ic Control Unit 1 5 THREE WAY CATALYTIC CONVERTER SYSTEM 1 17 AIR INDUCTION SYSTEM 1 19 INSTRUMENT PANEL 1 21 IMPORTANT INFORMATION 1 23 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 23 REPLACEMENT PARTS 1 23 GASKETS OIL SEALS AND O RINGS 1 23 LOCK WASHERS PLATES AND COTTER PINS 1 24 BEARINGS AND OIL SEALS 1 24 CIRCLIPS 1 24 CHECKING THE CONNECTIONS 1 25 SPECIAL TOOLS 1 26 ...

Page 11: ...GEN INFO ...

Page 12: ...TORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 2 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...spite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operating under a heavy load Carburetors that me ter the fuel through the use of jets have been provided with various auxiliary devices so that an opti mum air fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the...

Page 14: ...jected into the intake manifold only during the time the passage remains open Therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied Conversely the shorter the length of time the injector is energized injection duration the lesser the volume of fuel that is supplied The injection duration and the injection timing are con...

Page 15: ...ure detection Coolant temperature sensor Coolant temperature detection Intake air temperature sensor Intake air temperature detection Throttle position sensor Throttle angle detection O2 sensor Gas emission O2 concentration detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine PRM detection Speed sensor Speed detec...

Page 16: ...he CPU and input them into the CPU C CPU Central Processing Unit The CPU determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor Then the signals are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection timing and ...

Page 17: ...he model for Europe the ECU causes the headlight relay 2 to output a constant ON signal provided that the main switch is ON On the model for Australia the ECU controls the headlight relay 2 in accordance with the engine speed as required by the daytime illumination specification 3 Operating the radiator fan motor in accordance with the coolant temperature The ECU controls the radiator fan motor re...

Page 18: ...s any debris in the fuel tank from entering the fuel sys tem downstream of the pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose becomes clogged This valve opens when the fuel pressure at the discharge ou...

Page 19: ...gm in the direction for closing the valve in contrast to the pressure of the fuel Thus the valve cannot open unless the fuel pressure overcomes the spring force An intake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the diaphragm opens allowing the fuel to return from the...

Page 20: ...signal from the ECU the core is drawn up ward allowing the flange that is integrated with the needle to move to the spacer Since the distance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in pr...

Page 21: ...orce is generated in the coil The voltage of this force is then input into the ECU which calculates the position of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calculated data in order to determine the corresponding injection timing Based on the changes in the time intervals of the signals generated by the pickup coil the ECU calculates ...

Page 22: ...on sensor The cylinder identification sensor is mounted on the exhaust head cover of the 1 cylinder When the exhaust cam of the 1 cylinder rotates and the projection of the cam plate passes by the sensor the sensor generates a signal and sends it to the ECU Based on this signal and the signal from the crank shaft position sensor the ECU then actuates the injector of the cylinder that is currently ...

Page 23: ... volume by detecting the position of the throttle valve It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board In actual opera tion the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to de...

Page 24: ...al signals and sends those signals to the ECU When the intake air pressure is introduced into the sensor unit which contains a vacuum chamber on one side of the silicon diaphragm the silicon chip that is mounted on the silicon diaphragm converts the in take air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in or...

Page 25: ...o the ECU Intake air temperature sensor The intake temperature sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures This sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance...

Page 26: ...irconia tube is in contact with the exhaust gas and the interior is in contact with the atmosphere whose oxygen concentration level is known When a difference in the oxygen con centration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and generates an electromotive force The electromotive force increases when the oxygen c...

Page 27: ... the motorcycle However the voltage output to the ECU remains unchanged at the low level When the tilt of the motorcycle exceeds 70 degrees according to the tilt of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level voltage it determines that the motorcycle has overturned and stops the delivery of fuel to the engine by turning OFF ...

Page 28: ...uces the CO HC and NOx in the exhaust gases The FI system controls the mixture to an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion Furthermore an O2 sensor that detects the concentration of oxygen that remains in the exhaust gas is provided in the exhaust pipe for the purpose of maximizing the performance of t...

Page 29: ...ize with the oxidation function of platinum and are converted into harmless carbon dioxide CO2 and water H2O resulting in cleaner exhaust gases CO 1 2 O2 CO2 HC O2 CO2 H2O SThe NOx is reduced by the reduction function of rhodium which converts NOx into harmless nitro gen N2 and oxygen O2 resulting in cleaner exhaust gases NOx N2 O2 To clean the exhaust gases at a high rate of efficiency through th...

Page 30: ... air cut off valve and introduces it directly into the exhaust port through the reed valve The air cut off valve is controlled by the signals from the ECU in accordance with the combustion condi tions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant temperature is below the specifie...

Page 31: ...A and thus keeps the air passage open As a result the air from the air cleaner passes through the air passage and flows into the reed valves of the cylin ders When the current flows to the solenoid coil in accordance with a signal from the ECU the plunger in the core becomes attracted towards the coil When this attraction force overcomes the pressure of the spring the valve is pulled in along with...

Page 32: ...he multi function meter on the instrument panel Based on the signals received from the sensors the ECU inputs the signals into the multi function me ter Then the conditions of the sensors appear on the clock and trip odometer display of the multi func tion meter NORMAL MODE Speed meter Fuel meter The symbol blinks when the gasoline is almost empty Trip odometer display Clock display CO ADJUSTMENT ...

Page 33: ...nt mode and DIAG mode 1 Press the SELECT button in order to switch the display to CO or DIAG 2 Simultaneously press the SELECT and RESET buttons for 2 seconds or more to select an item Diagnosis monitoring mode Refer to TROUBLESHOOTING in chapter 7 CO adjustment mode Refer to CO adjustment in chapter 3 The engine cannot be started in this mode CO ADJUSTMENT MODE Cylinder identification For 1 For 2...

Page 34: ...ean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance...

Page 35: ...ers are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways re...

Page 36: ...ains Connect and disconnect sev eral times 3 Check Sall connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect Slead Scoupler Sconnector Make sure all connections are tight 5 Check Scontinuity with the pocket tester Pocket tester 90890 03112 SIf there is no continuity clean the terminals SWhen checking the wire harness perform steps 1 to 3 SAs ...

Page 37: ...embly cover 90890 01304 Piston pin puller This tool is used to remove the piston pin 90890 01325 90890 01352 Radiator cap tester Radiator cap tester adapter This tester is needed for checking the cooling system 90890 01362 90890 01382 Flywheel puller Crankshaft protector These tools are used to remove the A C magneto 90890 01367 90890 01374 Fork seal driver weight Fork seal driver attachment 43 mm...

Page 38: ...he vacuum pressure 90890 03081 90890 04136 Compression gauge Compression gauge adapter This gauge and adapter are used to measure the engine compression 90890 03094 Vacuum gauge This gauge is needed for carburetor synchronization 90890 03132 Pocket tester This instrument is invaluable for checking the electrical system 90890 03113 Engine tachometer This tool is needed for detecting engine rpm 9089...

Page 39: ...alve lifter 90890 04019 90890 04108 Valve spring compressor Valve spring compressor attachment These tools are needed to remove and install the valve assemblies 90890 04058 90890 04078 Middle driven shaft bearing driver Mechanical seal installer These tools are needed to install the water pump seal 90890 04086 Universal clutch holder This tool is used to hold the clutch when removing or installing...

Page 40: ......

Page 41: ...LE 2 18 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 24 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 25 OIL FLOW DIAGRAMS 2 26 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING 2 34 ...

Page 42: ...SPEC ...

Page 43: ...ll length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 180 mm 800 mm 1 290 mm 825 mm 1 485 mm 160 mm 2 900 mm SSS SSS SSS SSS SSS SSS SSS Weight Wet with oil and a full fuel tank Dry without oil and fuel Maximum load total of cargo rider passenger and accessories 221 kg 190 kg 203 kg SSS SSS SSS ...

Page 44: ...200 r min 33 X 36 kPa 1 500 kPa 15 kg cm2 15 bar at 400 r min SSS SSS SSS SSS SSS SSS SSS SSS Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular unleaded gasoline EUR Unleaded gasoline only OCE 20 L 3 5 L SSS SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replaceme...

Page 45: ...adiator cap opening pressure Valve relief pressure Radiator core Width Height Depth Coolant reservoir Capacity From low to full level Water pump Water pump type Reduction ratio Max impeller shaft tilt 1 7 L 95 0 X 125 0 kPa 0 95 X 1 25 kg cm2 0 95 X 1 25 bar 343 X 441 kPa 3 5 X 4 5 kg cm2 3 5 X 4 5 bar 300 mm 161 4 mm 27 mm 0 25 L 0 1 L Single suction centrifugal pump 44 44 38 27 1 407 SSS SSS SSS...

Page 46: ...p clearance Intake camshaft lobe dimensions Measurement A Measurement B Exhaust camshaft lobe dimensions Measurement A Measurement B Max camshaft runout Chain drive right 25 000 X 25 021 mm 24 967 X 24 980 mm 0 020 X 0 054 mm 35 70 X 35 80 mm 27 95 X 28 05 mm 35 70 X 35 80 mm 27 95 X 28 05 mm SSS SSS SSS SSS 0 08 mm 35 60 mm 27 85 mm 35 60 mm 27 85 mm 0 03 mm ...

Page 47: ...t width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 25 9 X 26 1 mm 27 9 X 28 1 mm 2 1 X 2 5 mm 2 1 X 2 5 mm 0 9 X 1 1 mm 0 9 X 1 1 mm 0 8 X 1 2 mm 0 8 X 1 2 mm 5 475 X 5 490 mm 5 460 X 5 475 mm 5 500 X 5 512 ...

Page 48: ...ed Intake Exhaust Compressed spring force installed Intake Exhaust Spring tilt Intake Exhaust Winding direction top view Intake Exhaust 37 3 mm 37 3 mm 30 4 mm 30 4 mm 98 1 X 113 8 N 10 0 X 11 6 kgf 98 1 X 113 8 N 10 0 X 11 6 kgf SSS SSS Clockwise Clockwise 35 4 mm 35 4 mm SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 1 7 mm SSS SSS ...

Page 49: ...set Offset direction Piston pins Outside diameter Piston pin to piston pin bore clearance Piston rings Top ring Ring type Dimensions B T End gap installed Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance 0 025 X 0 050 mm 91 960 X 91 975 mm 10 mm 21 004 X 21 015 mm 1 mm Intake side 20 991 X 21 000 mm 0 004 X 0 024 mm Barrel 1 2 3 5 mm 0 20 X 0 35 mm 0 03 X...

Page 50: ... end side clearance D Crankshaft journal to crankshaft journal bearing clearance Bearing color code Position of thrust bearing 60 75 X 61 25 mm 150 1 X 150 9 mm SSS 0 110 X 0 262 mm 0 020 X 0 038 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red 2 JOURNAL SSS SSS 0 02 mm 0 50 mm 0 10 mm SSS SSS Balancer Balancer drive method Gear SSS Clutch Clutch type Clutch release method Operation Clutch ...

Page 51: ...3rd gear 4th gear 5th gear 6th gear Max main axle runout Max drive axle runout Constant mesh 6 speed Spur gear 67 39 1 718 Chain drive 42 16 2 625 Left foot operation 33 12 2 750 37 19 1 947 34 22 1 545 31 25 1 240 26 25 1 040 24 26 0 923 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0 08 mm 0 08 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending Shift drum and g...

Page 52: ... Standard Limit Throttle bodies Model manufacturer quantity Intake vacuum pressure Throttle cable free play at the flange of the throttle grip ID mark Throttle valve size 38EIS MIKUNI 2 33 X 36 kPa 3 X 5 mm 5PS1 00 50 SSS SSS SSS SSS SSS ...

Page 53: ...SSS SSS 1 mm 0 5 mm Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17M C MT5 00 Aluminum 133 mm SSS SSS SSS SSS SSS SSS 1 mm 0 5 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 90 X 208 kg High speed riding Min tire tread depth Tubeless 120 70ZR 18M C 59W MEZ4J FRONT METZELER D220FSTJ DUNLOP...

Page 54: ...ckness Max deflection Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm SSS SSS 5 5 mm 14 mm 30 2 mm and 27 mm SSS SSS SSS SSS 4 5 mm 0 1 mm 0 5 mm SSS SSS Rear brake Brake type Operation Brake pedal position below the top of the rider footrest Recommended fluid Brake discs Diameter thickness Min thicknes...

Page 55: ...ut the fork spring Inner tube outer diameter Inner tube bend Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Telescopic fork Coil spring oil damper 150 mm 314 mm 150 mm 306 mm 6 86 N mm 0 686 kgf mm 9 32 N mm 0 932 kgf mm 0 X 80 mm 80 X 150 mm No Yamaha fork oil 10 WT or equivalent 507 cm3 133 mm 43 mm SSS 8 7 1 1 2 4 SSS SSS...

Page 56: ...aximum from the fully turned in position Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 61 5 mm 180 mm 170 mm 127 5 mm 12 75 kgf mm 0 X 61 5 mm No 1 200 kPa 12 0 kg cm2 12 0 bar 1 5 9 20 12 3 12 11 1 SSS SSS SSS 176 4 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Swingarm Free play ...

Page 57: ...Charging system System type Model manufacturer Nominal output Stator coil resistance color A C magneto LNZ86 DENSO 14 V 31 5 A at 5 000 r min 0 18 X 0 28 Ω W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacturer No load regulated voltage Rectifier capacity Withstand voltage Semiconductor short circuit FH001 SHINDENGEN 14 1 X 14 9 V 35 A 200 V SSS SSS SSS SSS SSS Battery Battery t...

Page 58: ... manufacturer Amperage Coil resistance MS5F 621 JIDECO 180 A 4 18 X 4 62 Ω SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil resistance Plane YF 12 NIKKO 1 3 A 105 X 113 db 2 m 1 15 X 1 25 Ω SSS SSS SSS SSS SSS Turn signal relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE218BH DENSO No 75...

Page 59: ...use Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Hazard light fuse Parking light fuse Backup fuse Reserve fuse 40 A 1 15 A 1 15 A 1 7 5 A 1 EUR 10A 1 OCE 10 A 1 20 A 1 10 A 1 5 A 1 5 A 1 20 A 1 15 A 1 10 A 1 7 5 A 1 EUR 5 A 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 60: ...ral tightening torques 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO I...

Page 61: ...Oil filter element drain bolt Air filter case Surge tank Solenoid valve Exhaust check bolt Exhaust pipe Exhaust pipe Muffler joint Muffler O2 sensor protector Crankcase initial 2nd Bolt Bolt Screw Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Bolt Bolt Screw Screw Bolt Nut Bolt Bolt Bolt Bolt Bolt M6 M6 M12 M5 M6 M9 M12 M7 M6 M6 M5 M6 M6 M10 M6 M6 M14 M6 M6 M10 M6 M5 M...

Page 62: ...er bolt Clutch cover Bolt Bolt Bolt Screw Nut Screw Nut Nut Screw Bolt Bolt Bolt Nut Nut Bolt Bolt Screw Bolt Bolt Screw Bolt Bolt Bolt M6 M8 M6 M6 M20 M6 M22 M10 M5 M6 M6 M6 M6 M6 M6 M8 M8 M6 M5 M6 M6 M12 M12 M18 M6 M6 2 2 3 6 1 3 1 1 1 1 2 1 1 1 1 1 1 3 2 2 2 1 1 1 6 9 10 24 10 8 70 12 85 20 4 10 12 12 8 8 10 22 22 10 4 4 10 18 18 45 10 10 1 0 2 4 1 0 0 8 7 0 1 2 8 5 2 0 0 4 1 0 1 2 1 2 0 8 0 8 ...

Page 63: ...2 21 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence Upper crankcase Lower crankcase ...

Page 64: ... Frame and rear frame Pivot shaft and nut Swingarm and connecting arm Relay arm and connecting arm Relay arm and rear shockabsorber Relay arm and frame Rear shock absorber and upper bracket Upper bracket and frame Chain case and swingarm Chain protector and swingarm Brake hose holder and swingarm Pivot shaft adjusting bolt Frame and fuel tank rear Frame and fuel tank front Grab bar Sidestand and s...

Page 65: ... brake caliper and caliper bracket M10 27 2 7 Front brake disc and wheel M6 18 1 8 Rear brake disc and wheel R h l k d h b M8 M10 20 69 2 0 6 9 Rear wheel sprocket and hub Bl d M10 M8 69 6 6 9 0 6 Bleed screw F t h l l i h b lt M8 M8 6 20 0 6 2 0 Front wheel axle pinch bolt R b k li b k t d i M8 M10 20 40 2 0 4 0 Rear brake caliper bracket and swing arm M10 40 4 0 1 First tighten the lower ring nu...

Page 66: ...Oil pump rotors inner and outer Oil pump housing Oil strainer Pull rod and clutch cover Shift shaft left side and crankcase Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft right side and crankcase Shift pedal bolt Cylinder head cover mating su...

Page 67: ... wheel drive hub mating surface Rear brake pedal pivot Rear footrest pivoting point Sidestand pivoting point and metal to metal moving parts Throttle grip inner surface Clutch lever pivot bolt and clutch cable end Hooks Engine mounting bolts and nuts rear upper and lower Brake lever pivot bolt and contact surface Rear shock absorber assembly mounting bolts Pivot shaft Connecting arm bearing Spacer...

Page 68: ...2 26 1 Scavenge pump 2 Feed pump 3 Oil strainer 4 Oil filter element 5 Oil drain bolt oil tank 6 Oil tank 7 Oil level switch OIL FLOW DIAGRAMS SPEC OIL FLOW DIAGRAMS ...

Page 69: ...2 27 OIL FLOW DIAGRAMS SPEC 1 Front balancer shaft 2 Oil strainer 3 Feed pump 4 Relief valve 5 Scavenge pump ...

Page 70: ...2 28 OIL FLOW DIAGRAMS SPEC 1 Cam shaft 2 Rear balancer shaft 3 Main axle 4 Drive axle 5 Oil drain bolt engine 6 Front balancer shaft ...

Page 71: ...2 29 OIL FLOW DIAGRAMS SPEC 1 Cylinder head 2 Rear balancer shaft 3 Crankshaft 4 Oil drain bolt engine ...

Page 72: ...2 30 OIL FLOW DIAGRAMS SPEC 1 Main axle 2 Drive axle ...

Page 73: ...2 31 1 Radiator 2 Water pump 3 Radiator outlet hose 4 Thermostat assembly 5 Thermostat inlet hose 6 Radiator inlet hose COOLING SYSTEM DIAGRAMS SPEC COOLING SYSTEM DIAGRAMS ...

Page 74: ...2 32 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Radiator outlet hose 3 Water pump 4 Coolant reservoir tank hose ...

Page 75: ...2 33 COOLING SYSTEM DIAGRAMS SPEC 1 Thermostat assembly 2 Thermostat inlet hose 3 Liner control valve ...

Page 76: ...d 18 Auxiliary light lead 19 Front turn signal light left 20 Stay 3 21 Headlight sub wire harness 22 Headlight coupler 1 Throttle cables 2 Clutch cable 3 Handlebar switch lead left 4 Main switch lead 5 Cover 7 6 Horn lead 7 Horn 8 Cover 8 9 Front brake hose 10 Handlebar switch lead right 11 Front fork CABLE ROUTING SPEC CABLE ROUTING ...

Page 77: ...K Fasten the horn lead to the front fork left side with a clamp as shown in the drawing Cut the clamp tip with 3 to 8 mm left A Fasten the handlebar switch lead left to the han dlebar with a band B Through the handlebar switch lead left and clutch cable to the wire guide on the upper bracket C Fasten the main switch lead to the wire guide with a clamp There should be no slack between main switch a...

Page 78: ... headlight adjusting knob V Clamp the headlight sub wire harness to the stay 1 L Fasten the main switch lead with a clamp so that it faces the front side of the vehicle M Fasten the turn signal lead right together with the coupler to the stay 1 N Clamp the headlight sub wire harness aligned with the white tape O Fasten the wire harness and turn signal lead left together with the coupler to the sta...

Page 79: ...5 Tail brake light lead 16 Rear turn signal light left 17 Rear turn signal light lead 18 Rectifier regulator lead 19 Rear suspension 20 Swingarm 21 Sidestand switch 22 Sidestand switch lead CABLE ROUTING SPEC 1 Plate 2 Stay 3 3 Ignition coil 4 Neutral switch lead 5 O2 sensor lead 6 Speed sensor lead 7 Sidestand switch lead 8 Crankshaft position sensor lead 9 Air filter case drain hose 10 Coolant r...

Page 80: ...d be under the clamp The position is regardless of ranks Make the end clearances of coolant reservoir tank drain hose and air filter case drain hose from the clamp even with that of fuel drain hose A To the headlight B Connect the headlight sub wire harness in front of ECU and make it not to route inside or above the ECU lead C Fasten the wire harness to the stay 1 with a clamp The knot should be ...

Page 81: ...n hose and air filter case drain hose behind the battery negative lead K The O2 sensor lead should not stick out from the boss seat face to the outside of the vehicle L Bind the neutral switch O2 sensor speed sensor sidestand switch and rectifier regulator leads with the clamp Cut the tip with 3 to 8 mm left and make it face to the outside of the vehicle M Fasten the ECU lead with the clamp instal...

Page 82: ...h lead 8 Starter relay lead 9 Coolant reservoir tank drain hose 10 Rear brake light switch 11 Fuel return hose 12 Fuel hose 13 Fuel drain hose A Route the clutch cable through the guide of stay 2 B Pass the fuel hose between the fuel drain hoses C Direct the take out port of rear brake light switch lead to the front ...

Page 83: ...re sensor 19 Main fuse 20 Starter relay 21 Rear turn signal light lead right 22 Rear turn signal light right 23 Tail brake light lead 24 Tail brake light 25 Rear turn signal light lead left 26 Rear turn signal light left 27 Alarm coupler 28 Seat lock cable 29 Fuse box 30 Battery band 31 Battery negative lead 32 Radiator fan relay 33 Starting circuit cut off relay 34 Fuel pump lead 2 35 Fuel pump l...

Page 84: ...f rear turn signal lead left by folding and then bundle it A For the wire harness routing use clamps to fasten the wire harness to the outer hole of the cover 2 B To the AI system C Plug in the ignition coil lead terminals as shown in the drawing both left and right D For the throttle cable the upper side should be the return side and the lower side should be the pull side E Fasten the coolant res...

Page 85: ...en the cover and the harness Position the clamp at the closer point than the cou pler to the right side of the vehicle body as shown in the illustration L Route the rear turn signal lead left through the left side hole of fender M Route the rear turn signal light leads right and left between the ribs of rear fender N Route the seat lock cable through the hole section of the seat bracket of rear fr...

Page 86: ...on the clamp tip to face downward AA Route the wire harness through the smaller diam eter and the radiator reservoir tank drain hose through the larger diameter and clamp them BB Place the radiator reservoir tank hose up and the thermo wax hose down and then clamp them Attach the clamp with its open section downward CABLE ROUTING SPEC ...

Page 87: ......

Page 88: ...T GAS AT IDLE 3 18 ADJUSTING THE EXHAUST GAS VOLUME 3 20 CHECKING THE EXHAUST GAS AT IDLE 3 22 ADJUSTING THE ENGINE IDLING SPEED 3 24 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 25 CHECKING THE SPARK PLUGS 3 27 CHECKING THE IGNITION TIMING 3 28 MEASURING THE COMPRESSION PRESSURE 3 29 CHECKING THE ENGINE OIL LEVEL 3 30 CHANGING THE ENGINE OIL 3 32 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 34 CHECKING THE...

Page 89: ...ACK 3 50 LUBRICATING THE DRIVE CHAIN 3 51 CHECKING AND ADJUSTING THE STEERING HEAD 3 52 CHECKING THE FRONT FORK 3 55 ADJUSTING THE FRONT FORK LEGS 3 55 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 57 CHECKING THE TIRES 3 59 CHECKING THE WHEELS 3 61 CHECKING AND LUBRICATING THE CABLES 3 62 LUBRICATING THE LEVERS AND PEDALS 3 62 LUBRICATING THE SIDESTAND 3 62 LUBRICATING THE REAR SUSPENSION 3 62 ELE...

Page 90: ...ean and regap Ǹ Ǹ See page 3 27 S Replace Ǹ Ǹ 3 Valves See page 3 10 S Check valve clearance S Adjust Every 40 000 km 4 Air filter element See page 3 35 S Replace Ǹ 5 Clutch See page 3 34 S Check operation S Adjust Ǹ Ǹ Ǹ Ǹ Ǹ 6 Front brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 6 See page 3 45 S Replace brake pads Whenever worn to the limit 7 Rear brake S Check oper...

Page 91: ...32 S Replace Ǹ Ǹ Ǹ 24 Cooling system S Check coolant level and vehicle for coolant leakage Ǹ Ǹ Ǹ Ǹ Ǹ 24 g y See page 3 38 S Change Every 3 years 25 Front and rear brake switches See page 3 47 S Check operation Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 26 Moving parts and cables See page 3 62 S Lubricate Ǹ Ǹ Ǹ Ǹ Ǹ 27 Air induction system See page 7 39 S Check the air cut off valve read valve and hose for damage S Replace the en...

Page 92: ...3 3 SEAT CHK ADJ Order Job Part Q ty Remarks 1 Removing the seat Seat 1 Remove the parts in the order listed For installation reverse the removal procedure EAS00038 SEAT ...

Page 93: ...Windshield Inner panel Turn signal light connector Side cowling left and right Front cowling Air intake grile Headlight assembly 1 1 2 2 1 2 1 Remove the parts in the order listed Disconnect For installation reverse the removal procedure FRONT COWLINGS CHK ADJ FRONT COWLINGS ...

Page 94: ...uel hose Fuel tank breather hose Fuel pump coupler Fuel sender coupler Fuel tank 2 2 2 1 1 1 Remove the parts in the order listed Refer to SEAT Refer to FRONT COWLINGS For installation reverse the removal procedure Disconnect 16 Nm 1 6 mSkg 4 Nm 0 4 mSkg 7 Nm 0 7 mSkg 16 Nm 1 6 mSkg 4 Nm 0 4 mSkg EAS00040 FUEL TANK ...

Page 95: ...l when removing the fuel hoses since there may be fuel remain ing in it Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Sfuel tank Do not set the fuel tank down so that the installa tion surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position REMOVING THE FUEL PUMP 1 Remove Sfuel pump SDo not drop the f...

Page 96: ...lways use a new fuel pump gasket SInstall the fuel pump as shown in the illustra tion STighten the fuel pump bolts in stages in a criss cross pattern and to the specified torque INSTALLING THE FUEL HOSE 1 Install Sfuel hose Sfuel hose holders When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct position otherwise the fuel hose will...

Page 97: ...rear cowling Seat Grab bar Tail brake light coupler Rear cowling 1 1 1 Remove the parts in the order listed Refer to SEAT Disconnect For installation reverse the removal procedure 23 Nm 2 3 mSkg 23 Nm 2 3 mSkg 19 Nm 1 9 mSkg 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg EAS00042 REAR COWLING ...

Page 98: ...ylinder head breather hose AI system hose Solenoid valve hose Solenoid valve coupler Atmospheric temperature sensor coupler Drain hose Air filter case 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT Refer to FUEL TANK For installation reverse the removal procedure 7 Nm 0 7 mSkg Disconnect EAS00043 AIR FILTER CASE ...

Page 99: ... Sside cowlings Refer to FRONT COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE 2 Remove Sair cut off valve Refer to AIR CUT OFF VALVE AND REED VALVE in chapter 7 3 Drain Scoolant Refer to CHANGING THE COOLANT 4 Remove Sradiator Refer to RADIATOR in chapter 6 Sthermostat assembly Refer to RADIATOR in chapter 6 5 Remove Scylinder head cover Refer to CYLINDER HEAD COV...

Page 100: ...correct record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft counterclockwise as spe cified in the following table B Degrees that the crankshaft is turned counter clockwise C Cylinder D Combustion cycle Cy...

Page 101: ...the correct place b Select the proper valve pad from the follow ing table Valve pad thickness range Available valve pads Nos 120 X 240 1 20 X 2 40 mm 25 thicknesses in 0 05 mm increments SThe thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter SSince valve pads of various sizes are originally installed the valve pad number must be rounded ...

Page 102: ...ber is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lift er 2 SLubricate the valve pad with molybdenum dis ulfide grease SLubricate the valve lifter with molybdenum dis ulfide oil SThe valve lifter must turn smoothly when ro tated by hand SInstall the valve ...

Page 103: ...215 220 225 230 235 240 1 01 X 1 05 205 210 215 220 225 230 235 240 1 06 X 1 10 210 215 220 225 230 235 240 1 11 X 1 15 215 220 225 230 235 240 1 16 X 1 20 220 225 230 235 240 1 21 X 1 25 225 230 235 240 1 26 X 1 30 230 235 240 1 31 X 1 35 235 240 1 36 X 1 40 240 EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 X 0 02 120 125 130 135 ...

Page 104: ...cifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 9 Apply Ssealant onto the cylinder head cover Yamaha bond No 1215 90890 85505 10 Install Scylinder head cover EAS00050 SYNCHRONIZING THE THROTTLE BODIES Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim i...

Page 105: ...al minutes 7 Check Sengine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 1 100 X 1 200 r min 8 Adjust Sthrottle body synchronization a With throttle body 1 as standard adjust throttle body 2 using the air screws 1 SAfter each step rev the engine two or three times each time for less than a second and check the synchronization again SIf the ...

Page 106: ...should not exceed 1 33 kPa 10 mm Hg 9 Measure Sengine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 10 Stop the engine and remove the measuring equipment 11 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 X 5 mm 12 Remove Sengine tachometer Svacuum ga...

Page 107: ...EAT Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE Sexhaust pipe bolts 1 3 Install Spocket tester 1 onto the engine oil drain bolt Sengine tachometer onto the spark plug lead of cylinder 1 Sexhaust attachment 2 onto the exhaust pipe Pocket tester 90890 03132 Engine tachometer 90890 03113 Exhaust attachment 90890 03134 4 Stop air induction system operation Crimp the hose a ...

Page 108: ...erature 60 X 80_C 7 Measure Sengine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 1 100 X 1 200 r min 8 Install SCO HC tester 1 onto the exhaust attachment 9 Measure Scarbon monoxide density Out of specification Adjust Within specification Measure the exhaust gas when induction system is operating Carbon monoxide density when air induction ...

Page 109: ...To switch to the CO adjusting mode 1 Push the SELECT button to switch the display between the CO adjusting mode and the DIAG mode 2 Push the SELECT button and RESET button together for more than two se conds to set the desired mode c To select the cylinder to be adjusted SPush the SELECT button or the RESET button to select the cylinder The number of the cylinder to be adjusted will be indicated o...

Page 110: ...ted on the display SPush the RESET button to increase the vol ume SPush the SELECT button to decrease the volume SRelease the button to set the volume SPush the SELECT button and the RESET button together to return to the selected cyl inder e To deactivate the mode set the main switch OFF ...

Page 111: ...fer to SEAT Sfuel tank Refer to FUEL TANK 3 Install Spocket tester 1 onto the engine oil drain bolt Sengine tachometer onto the spark plug lead of cylinder 1 Pocket tester 90890 03132 Engine tachometer 90890 03113 4 Install Sfuel tank Refer to FUEL TANK 5 Start the engine and warm it up until the spe cified oil temperature is reached Oil temperature 60 X 80_C 6 Measure Sengine idling speed Out of ...

Page 112: ...ube as shown in the illustration SBe sure to set the heat resistant rubber tube so that exhaust gas does not leak out SBefore using the carbon monoxide and hydro carbon tester be sure to read the user s manu al 8 Measure Scarbon monoxide density Shydrocarbon density Carbon monoxide density when air induction system is operating Below 1 Reference value Out of specification Check air induction syste...

Page 113: ...eter onto the spark plug lead of cylinder 1 Engine tachometer 90890 03113 3 Measure Sengine idling speed Out of specification Adjust Engine idling speed 1 100 X 1 200 r min 4 Adjust Sengine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is Direction g g p increased Direction Engine idling speed is ...

Page 114: ...lay at the flange of the throttle grip 3 X 5 mm 2 Remove Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE 3 Adjust Sthrottle cable free play When the throttle is opened the accelerator cable 1 is pulled Carburetor side a Loosen the locknut 2 on the decelerator cable b Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable c Loosen the lock...

Page 115: ...side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased c Tighten the locknut After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this d...

Page 116: ...al ling into the cylinders 3 Check Sspark plug type Incorrect Replace Spark plug type manufacturer DPR8EA 9 NGK X24EPR U9 DENSO 4 Check Selectrode 1 Damage wear Replace the spark plug Sinsulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Sspark plug with a spark plug cleaner or wire brush 6 Measure Sspark plug gap a with a wire Thickness gauge Out of specif...

Page 117: ...ht 1 Sengine tachometer onto the spark plug lead of cylinder 1 Timing light 90890 03141 Engine tachometer 90890 03113 3 Check Signition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed Engine idling speed 1 100 X 1 200 r min b Check that the stationary pointer a is within the firing range b on the generator rotor Incorrect firing r...

Page 118: ...eral min utes and then turn it off 3 Disconnect Sspark plug cap 4 Remove Sspark plug Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 5 Install Scompression gauge 1 Compression gauge 90890 03081 Compression gauge adapter 90890 04136 6 Measure Scompression pressure Out of specification Refer ...

Page 119: ...rfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and mea sure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Pisto...

Page 120: ...s best suited for certain atmospheric temperatures API standard SE or higher grade ACEA standard G4 or G5 SEngine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERV ING II b or higher SDo not allow foreign materials to...

Page 121: ...th the gasket 4 Drain Sengine oil completely from the crankcase and oil tank 5 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Install the new O ring 3 new oil filter ele ment and the oil filter element cover Oil filter element cover bolt 10 Nm 1 0 mSkg 6 Install Sengine oil drain bolt engine along ...

Page 122: ...min utes and then turn it off 11 Check Sengine for engine oil leaks 12 Check Sengine oil level Refer to CHECKING THE ENGINE OIL LEVEL 13 Check Sengine oil pressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check ...

Page 123: ...ntil the specified clutch cable free play is ob tained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased c Tighten the locknut If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Loosen the locknuts 1 b Turn the adjusting bolt 2 in direction a or b until the sp...

Page 124: ... if you are riding in unusually wet or dusty areas 4 Install Sair filter element Sair filter case cover Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the FI tuning leading to poor engine perfor mance and possible overheating When i...

Page 125: ...case Refer to AIR FILTER CASE 2 Check Sfuel hose 1 Cracks damage Replace Loose connection Connect properly 3 Install Sfuel tank Sair filter case EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE 2 Check Scrankcase breather hose 1 Cracks damage Replace Loose connection Connect properly Make sure the crankcase breather hose...

Page 126: ...lers and gaskets 1 Check Sexhaust pipe 1 Smuffler 2 Cracks damage Replace Sgasket 3 Exhaust gas leaks Replace 2 Check Stightening torque Exhaust pipe nut 4 20 Nm 2 0 mSkg Exhaust pipe bolt 5 24 Nm 2 4 mSkg Exhaust pipe and muffler bolt 6 20 Nm 2 0 mSkg Muffler and muffler bracket bolt 7 24 Nm 2 4 mSkg O2 sensor protector bolt 8 10 Nm 1 0 mSkg ...

Page 127: ...ark b Below the minimum level mark Add the recommended coolant to the proper level SAdding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant SUse only distilled water However if dis tilled water is not available soft water may be used 4 Start the engine warm it up fo...

Page 128: ...e Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE 2 Check Sradiator 1 Sradiator inlet hose 2 Sradiator outlet hose 3 Sradiator reservoir tank hose 4 Sradiator cover 5 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install Sfuel tank Sair filter case ...

Page 129: ...he radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his sing sound has stopped press down on the radiator cap and turn it counterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 5 Remove Scoolant dra...

Page 130: ...y wash them with water and consult a doc tor SIf coolant splashes on your clothes quick ly wash it away with water and then with soap and water SIf coolant is swallowed induce vomiting and get immediate medical attention SAdding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of ...

Page 131: ...Scoolant reservoir cap 13 Start the engine warm it up for several min utes and then stop it 14 Check Scoolant level Refer to CHECKING THE COOLANT LEV EL Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Sseat ...

Page 132: ...argest Position 5 Distance is the smallest SAfter adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial SA soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will co...

Page 133: ... pedal is raised Direction Brake pedal is lowered After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification Locknut 10 Nm 1 0 mSkg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brak...

Page 134: ...mended brake fluid DOT 4 A Front brake B Rear brake SUse only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water ...

Page 135: ... fluid reservoir is horizontal EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Sfront brake pad Srear brake pad Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to REPLACING THE FRONT BRAKE PADS and REPLACING THE REAR BRAKE PADS in chapter 4 A Front brake B Rear brake ...

Page 136: ... the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction Brake light comes on later EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Sbrake hoses 1 Cracks damage...

Page 137: ...engthening the bleeding procedure SIf bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Shydraulic brake system a Fill the brake fluid reservoir to the proper lev el with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid res...

Page 138: ... to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake operation EAS00137 ADJUSTING THE SHIFT PEDAL The shift pedal position is determined by the installed shift rod length a 1 Measure Sinstalled shift rod length a Incorrect Adjust Installed shift rod length 94 mm 2 Adjust Sinstalled shift rod length a a Loosen both locknuts 1 b Turn the shift rod 2 in directi...

Page 139: ...ose can skip and damage the swin garm or cause an accident Therefore keep the drive chain slack within the specified limits 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of drive chai...

Page 140: ...ut 16 Nm 1 6 mSkg f Tighten the wheel axle nut to specification Wheel axle nut 150 Nm 15 0 mSkg g Tighten the brake caliper bracket bolt to specification Brake caliper bracket bolt 40 Nm 4 0 mSkg EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced...

Page 141: ...ycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check Ssteering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Shandlebar holder 1 Shandlebar 2 4 Loosen Supper bracket pinch bolts 1 5 Remove Ssteering stem nut Supper bracket 2 ...

Page 142: ...to specification Do not overtighten the lower ring nut Lower ring nut final tightening torque 15 Nm 1 5 mSkg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 e Install the rubber washer 2 f Install the upper ring nut 3...

Page 143: ...ngle from the handlebar pull the spring gauge and then record the measurement when the handle bar starts to run Steering head tension 200 X 500 g e Repeat the above procedure on the opposite handlebar f If the steering head tension is out of specifi cation both handlebars should be within specification remove the upper bracket and loosen or tighten the upper ring nut g Reinstall the upper bracket ...

Page 144: ...nt fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK in chapter 4 EAS00154 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs SAlways adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability SSecurely support the...

Page 145: ...eload is decreased suspension is softer Adjusting positions Minimum 8 Standard 7 Maximum 1 Rebound damping Never go beyond the maximum or minimum adjustment positions 1 Adjust Srebound damping a Turn the adjusting screw 1 in direction a or b Direction Rebound damping is increased suspension is harder Direction Rebound damping is decreased suspension is softer Adjusting positions Minimum 1 Standard...

Page 146: ...lling over Spring preload Never go beyond the maximum or minimum adjustment positions 1 Adjust Sspring preload a Turn the adjusting ring 1 in direction a or b b Align the desired position on the adjusting ring with the stopper 2 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting positions Minimum 1 Standard 5 Maximum 9 ...

Page 147: ...on is softer Adjusting positions Minimum 20 clicks out Standard 12 clicks out Maximum 3 clicks out from the fully turned in position Compression damping Never go beyond the maximum or minimum adjustment positions 1 Adjust Scompression damping a Turn the adjusting screw 1 in direction a or b Direction Compression damping is increased suspension is harder Direction Compression damping is decreased s...

Page 148: ... SOperation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 221 kg Maximum load 371 kg Cold tire pressure Front Rear Up to 90 kg load 250 kPa 2 5 kgf cm2 2 5 bar 250 kPa 2 5 kgf cm2 2 5 bar 90 kg X maximum load 250 kPa 2 5 kgf cm2 2 5 bar 290 kPa 2 9 kgf cm2 2 9 bar High speed riding 250 kPa 2 5 k...

Page 149: ...be are centered in the wheel groove SPatching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement A Tire B Wheel Tube wheel Tube tire only T beless wheel Tube or tubeless Tubeless wheel tire SAfter extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this...

Page 150: ...e Manufacturer Size Model DUNLOP 160 60ZR17 M C 69W D220STJ METZELER 160 60ZR17 M C 69W MEZ4J BRIDGE STONE 160 60ZR17 M C 69W BT020R PIRELLI 160 60ZR17 M C 69W MTR24 DRAGON GTS EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Swheel Damage out of round Replace Refer to CHECKING THE FRONT WHEEL in chapter 4 Never attempt to make any repairs to the wheel Aft...

Page 151: ...cate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease EAS00172 LUBRICATING THE SIDESTAND...

Page 152: ...electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL SSkin Wash with water SEyes Flush with water for 15 minutes and get immediate medical attention INTERNAL SDrink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion SThis is a sealed battery Never remove the sealing ...

Page 153: ...move Sseat Refer to SEAT 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Positive tester probe positive battery terminal Negative tester probe negative battery terminal SThe charge state of an MF battery can be checke...

Page 154: ...ed on the motorcycle disconnect the negative bat tery lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure the battery charger lead clips are in full contact with the b...

Page 155: ...ition checking steps If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the battery unuse...

Page 156: ... battery until the battery s charging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Set the charging time at 20 hours maximu...

Page 157: ...t Clean with a wire brush Loose connection Connect properly 9 Lubricate Sbattery terminals Recommended lubricant Dielectric grease 10 Install Sseat EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Sseat Refer to SEAT 2 Check Sfuse a Connect the pocket tester to the f...

Page 158: ... electrical circuit Fuses Amperage rating Q ty Main 40A 1 Fuel injection system 15A 1 Headlight 15A 1 Signaling system 7 5A EUR 10A OCE 1 Ignition 10A 1 Radiator fan motor 20A 1 Hazard light 10A 1 Parking light 5A 1 Backup 5A 1 Reserve 20 15 10 7 5 EUR 5A 1 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause exten...

Page 159: ...products and your hands away from the bulb until it has cooled down 5 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder 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 If the headlight bulb gets soiled thoroughly clean i...

Page 160: ...screwdriver 1 and then adjust the headlight height by inserting it from the downside b Turn the adjusting screw in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the headlight adjusting knob 2 in direc tion a or b Direction Headlight beam moves to the right Direction Headlight beam moves to the left ...

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Page 163: ...ALANCE 4 15 FRONT AND REAR BRAKES 4 16 FRONT BRAKE PADS 4 16 REAR BRAKE PADS 4 17 REPLACING THE FRONT BRAKE PADS 4 18 REPLACING THE REAR BRAKE PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE MASTER CYLINDER 4 25 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 27 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 28 ASSEMBLYING AND INSTALLIN...

Page 164: ...ERING HEAD 4 65 REAR SHOCK ABSORBER ASSEMBLY 4 66 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4 68 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 68 REMOVING THE REAR CHOCK ABSORBER ASSEMBLY 4 69 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 4 70 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 70 SWINGARM AND DRIVE CHAIN 4 72 REMOVING THE SWINGARM 4 74 REMOVING THE DRIVE CH...

Page 165: ...lar Brake disc Front wheel 1 2 1 2 2 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen For installation reverse the removal procedure NOTE 40 Nm 4 0 mSkg 40 Nm 4 0 mSkg 40 Nm 4 0 mSkg 40 Nm 4 0 mSkg 72 Nm 7 2 mSkg 20 Nm 2 0 mSkg 18 Nm 1 8 mSkg 18 Nm 1 8 mSkg EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS ...

Page 166: ... BRAKE DISCS CHAS Order Job Part Q ty Remarks Disassembling the front wheel Oil seal Bearing Collar 2 2 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 EAS00518 FRONT WHEEL ...

Page 167: ...over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Remove Sleft brake caliper Sright brake caliper Do not apply the brake lever when removing the brake calipers 3 Loosen Swheel axle pinch bolt Sfront wheel axle 4 Elevate Sfront wheel Place the motorcycle on a suitable stand so that the front wheel is elevated 5 Remove Sfront wheel axle 6 Remove Sfront wheel 7 Remov...

Page 168: ... Check Stire Refer to CHECKING THE TIRES in chapter 3 Sfront wheel Damage wear Replace 3 Measure Sradial wheel runout 1 Slateral wheel runout 2 Over the specified limits Replace Radial wheel runout limit 1 mm Lateral wheel runout limit 0 5 mm 4 Check Swheel bearings Front wheel turns roughly or is loose Replace the wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL and ASSEMBLING THE FRONT WHEE...

Page 169: ... handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 X 3 mm below the edge of the brake disc 3 Measure Sbrake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit minimum F...

Page 170: ... adjusted SAdjust the front wheel static balance with the brake discs installed 1 Remove Sbalancing weight s 2 Find Sfront wheel s heavy spot Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the wheel...

Page 171: ...s b and c until the front wheel is balanced 4 Check Sfront wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS00523 DISASSEMBLING THE FRONT WHEEL 1 Remove Soil seals 1 Swheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head scre...

Page 172: ...uter race 3 Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both of the brake discs 1 Lubricate Swheel axle Soil seal lips Recommended lubricant Lithium soap based grease 2 Install Scollars 3 Tighten Swheel axle 1 Swheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard ...

Page 173: ...ing bolt Wheel axle nut Washer Rear wheel axle Adjusting block Rear wheel 1 1 2 2 1 1 1 2 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen Loosen For installation reverse the removal procedure NOTE 27 Nm 2 7 mSkg 150 Nm 15 0 mSkg 40 Nm 4 0 mSkg EAS00550 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL ...

Page 174: ...t Q ty Remarks 1 2 3 4 5 6 7 8 Removing the brake disc and rear wheel sprocket Collar Rear wheel sprocket Oil seal Bearing Rear wheel drive hub Collar Damper Rear brake disc 2 1 1 1 1 1 6 1 For installation reverse the disassembly procedure 20 Nm 2 0 mSkg 69 Nm 6 9 mSkg ...

Page 175: ...SC AND REAR WHEEL SPROCKET CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Bearing Oil seal Spacer 2 1 1 Disassembly the parts in the order listed For installation reverse the disassembly procedure 1 2 3 EAS00560 ...

Page 176: ...Sbrake caliper bracket bolt 1 Do not depress the brake pedal when removing the brake caliper 3 Loosen Slocknut 1 left and right Sadjusting bolt 2 left and right 4 Remove Swheel axle nut 3 Swheel axle 4 Sadjusting block 5 left and right Srear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Sleft collar Srear wheel drive hub Srear wheel drive hub da...

Page 177: ...l sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket drive sprocket and drive chain as a set Refer to SWINGARM AND DRIVE CHAIN Bent teeth Replace the rear wheel sprock et drive sprocket and drive chain as a set Refer to ENGINE in chapter 5 b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace Srear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket ...

Page 178: ...ed lubricant Lithium soap based grease 2 Install Srear wheel drive hub damper Srear wheel drive hub Sleft collar 3 Install Srear wheel Sadjusting block left and right Swheel axle Swheel axle nut 4 Adjust Sdrive chain slack Drive chain slack 50 X 60 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 5 Tighten Slocknut left and right 1 Swheel axle nut 2 Sbrake caliper bracket bolt 3 ...

Page 179: ... WHEEL STATIC BALANCE SAfter replacing the tire wheel or both the rear wheel static balance should be adjusted SAdjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Srear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE ...

Page 180: ...ont brake pads Brake caliper bolt Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw 2 2 1 1 2 2 1 Remove the parts in the order listed For installation reverse the removal procedure 6 Nm 0 6 mSkg 40 Nm 4 0 mSkg EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 181: ...rt Q ty Remarks 1 2 3 4 Removing the rear brake pads Rear brake caliper Brake pad Brake pad shim Bleed screw 1 2 2 1 Remove the parts in the order listed For installation reverse the removal procedure 6 Nm 0 6 mSkg 27 Nm 2 7 mSkg REAR BRAKE PADS ...

Page 182: ...SUse only clean or new brake fluid for clean ing brake components SBrake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately SAvoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES SFlush with water for 15 minutes and get im mediate medical attention EAS00582 REPLACIN...

Page 183: ...pring Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 mSkg d Install a new brake pad shim onto the new brake...

Page 184: ... Sbrake caliper 6 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check Sbrake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 185: ...ad wear limit 1 Out of specification Replace the brake pads as a set Brake pad wear limit 0 8 mm 4 Install Sbrake pad shims onto the brake pads Sbrake pads Sbrake pad spring Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw Put the other end of the hose into an open container b Loosen the bleed screw and push t...

Page 186: ...ope based grease 6 Install Sbrake caliper 1 Sbrake caliper bolts 2 7 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check Sbrake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 187: ...nder Brake fluid Brake lever Front brake light switch lead coupler Front brake switch Union bolt Copper washer Master cylinder bracket Master cylinder assembly 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Disconnect For installation reverse the removal procedure 30 Nm 3 0 mSkg EAS00584 FRONT BRAKE MASTER CYLINDER ...

Page 188: ...rt Q ty Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body 1 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 EAS00585 ...

Page 189: ...r brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt Copper washer Brake hose Master cylinder assembly 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 30 Nm 3 0 mSkg 23 Nm 2 3 mSkg EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 190: ...art Q ty Remarks Disassembling the rear brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 EAS00587 ...

Page 191: ...the brake hose 3 Remove Sfront brake lever Sfront brake master cylinder bracket Sfront brake master cylinder assembly 4 Remove Scirclip into the front brake master cylinder Smaster cylinder kit EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove Sunion bolt 1 Scopper washers 2 Sbrake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of t...

Page 192: ... master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check Sbrake master cylinder kit 1 Damage scratches wear Replace C Front D Rear 3 Check Srear brake fluid reservoir 1 Cracks damage Replace Srear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check Sfront brake master cylinder reservoir 1 Cracks damage Replace Sfront brake master cylinder reservoir dia phra...

Page 193: ...linder holder with the UP mark facing up SAlign the end of the brake master cylinder holder with the punch mark a on the han dlebar SFirst tighten the upper bolt then the lower bolt 2 Install Scopper washers 1 New Sbrake hose 2 Sunion bolt 3 When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the projection a on the brake master cylinder Proper brake...

Page 194: ...reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 6 Bleed Sbrake system Refer to BLEEDING THE HYDRAULI...

Page 195: ...nstalling the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown 2 Fill Sbrake fluid reservoir Recommended brake fluid DOT 4 SUse only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake...

Page 196: ...M in chapter 3 4 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust Sbrake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest 32 mm 6 Adjust Srear brake light operation timing Refer to ADJUSTING THE REAR BRAKE L...

Page 197: ...e fluid Front brake caliper bolt Union bolt Copper washer Brake hose Brake caliper 2 1 2 1 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain For installation reverse the removal procedure 30 Nm 3 0 mSkg 40 Nm 4 0 mSkg EAS00613 FRONT BRAKE CALIPERS ...

Page 198: ...ake pad pin Brake pad spring Brake pad Shim Brake caliper piston Brake caliper piston seal kit Bleed screw 2 1 1 2 2 4 4 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 6 Nm 0 6 mSkg EAS00615 ...

Page 199: ...s 1 2 3 4 Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 30 Nm 3 0 mSkg 27 Nm 2 7 mSkg EAS00616 REAR BRAKE CALIPER ...

Page 200: ...assembling the rear brake caliper Brake pad Shim Brake pad spring Brake caliper piston Brake caliper piston seal kit Bleed screw 2 2 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 6 Nm 0 6 mSkg 1 2 3 4 5 6 EAS00617 ...

Page 201: ...sembly Put the end of the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake caliper piston seals 2 New a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper SNever try to pry out the brake caliper pis tons SDo ...

Page 202: ...liper Put the end of the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper piston 1 Sbrake caliper piston seals 2 New a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper SCover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper SNever try ...

Page 203: ...sembled 1 Check Sbrake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Sbrake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Sbrake caliper body Cracks damage Replace the brake cali per assembly Sbrake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper...

Page 204: ...rt SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper seals New Sbrake caliper pistons 2 Install Sbrake pad shims Sbrake pads Sbrake pad spring Sbrake pad pin Sbrake pad clips Refer to REPLACING THE BRAKE PADS 3 Install Sbrake caliper temporarily Sbrake caliper bolt Scopper washers 1 New Sbrake hose 2 Sunion bolt ...

Page 205: ...ce SWhen refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check Sbrak...

Page 206: ...ver a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper seals New Sbrake caliper piston 2 Install Sbrake pads Sbrake pad springs Sbrake caliper bolt Refer to REPLACING THE BRAKE PADS 3 Install Sbrake caliper 1 temporarily Scopper washers 2 New Sbrake hose 3 Sunion bolt 4 Proper brake hose routing is essential to in sure safe...

Page 207: ...nce SWhen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 6 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 7 Check Sbrake fluid lev...

Page 208: ...ose holder Cap bolt Upper bracket pinch bolt Lower bracket pinch bolt Front fork 1 2 1 2 2 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT AND REAR BRAKE For installation reverse the removal procedure Loosen 28 Nm 2 8 mSkg 26 Nm 2 6 mSkg 6 Nm 0 6 mSkg 10 Nm 1 0 mSkg 6 Nm 0 6 mSkg EAS00647 FRONT FORK ...

Page 209: ... fork legs Cap bolt O ring Washer Spacer Washer Fork spring Damper rod bolt Dust seal Oil seal clip Oil seal Washer Damper rod Inner tube 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed 23 Nm 2 3 mSkg 30 Nm 3 0 mSkg 1 2 3 4 5 6 7 8 9 10 11 12 13 EAS00648 ...

Page 210: ...4 46 FRONT FORK CHAS Order Job Part Q ty Remarks Oil lock piece Outer tube bushing Outer tube 1 1 1 For assembly reverse the disassembly procedure 23 Nm 2 3 mSkg 30 Nm 3 0 mSkg 14 15 16 ...

Page 211: ...anger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Remove Sfront brake caliper Refer to FRONT AND REAR BRAKE Sfront wheel Refer to FRONT WHEEL AND BRAKE DISCS 3 Remove Sfront fender 4 Loosen Supper bracket pinch bolt 1 5 Loosen Scap bolt 2 6 Loosen Slower bracket pinch bolts 3 Before loosening the upper and lower bracket pinch bolts support the ...

Page 212: ... the outer tube SIf the front fork leg protector must be removed always install a new one 4 Remove Sdamper rod assembly bolt Scopper washer While holding the damper rod with the damper rod holder 1 and T handle 2 loosen the damper rod assembly bolt Damper rod holder 29 mm 90890 01375 T handle 90890 01326 5 Remove Sinner tube a Hold the front fork leg horizontally b Slowly push the inner tube into ...

Page 213: ...Out of specification Replace Spring free length 314 mm Limit 308 mm 3 Check Sdamper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Soil flow stopper 2 Damage Replace SThe front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material SWhen disassembling and assembl...

Page 214: ...replace the following parts inner tube bushing outer tube bushing oil seal dust seal SBefore assembling the front fork leg make sure all of the components are clean 1 Install Sdamper rod Always use new copper washers Allow the damper rod to slide slowly down the inner tube until it protrudes from the bot tom of the inner tube Be careful not to dam age the inner tube 2 Lubricate Sinner tube s outer...

Page 215: ...ork seal driver attachment 90890 01374 5 Install Swasher Soil seal 1 New with the fork seal driver weight and fork seal driver attachment Make sure the numbered side of the oil seal faces up SBefore installing the oil seal lubricate its lips with lithium soap based grease SLubricate the outer surface of the inner tube with fork oil SBefore installing the oil seal cover the top of the front fork le...

Page 216: ...W or equivalent SBe sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance SWhen disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 Slowly stroke the inner tube 1 up and down 10 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Be s...

Page 217: ...and without the spring 133 mm 12 Install Sspring Sspring seat Sspacer Swasher Scap bolt 1 SInstall the spring with the smaller pitch a fac ing up SBefore installing the cap bolt apply grease onto the O ring SAlign the end of the cap bolt rod with the hole in the damper rod then install the cap bolt rod and temporarily install the cap bolt STemporarily tighten the cap bolt b larger pitch ...

Page 218: ... lower bracket pinch bolts Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Slower bracket pinch bolts 1 Scap bolt 2 Supper bracket pinch bolt 3 Make sure the brake hoses are routed prop erly 3 Install Sfront fender 4 Install Sfront wheel Refer to FRONT WHEEL AND BRAKE DISCS Sfront brake caliper Refer to FRONT AND REAR BRAKE 5 Adjust Sspring preload Srebound da...

Page 219: ...ch Grip end Handlebar grip left Clutch lever assembly Front brake light switch lead coupler Master cylinder assembly Master cylinder bracket Right handlebar switch Throttle cable housing Throttle cable Throttle grip Plug 2 1 1 1 1 2 1 1 1 1 1 1 1 2 1 4 Remove the parts in the order listed Disconnect Disconnect 26 Nm 2 6 mSkg 10 Nm 1 0 mSkg 26 Nm 2 6 mSkg 23 Nm 2 3 mSkg EAS00664 HANDLEBAR ...

Page 220: ...LEBAR CHAS Order Job Part Q ty Remarks 17 18 19 Upper handlebar holder Handlebar Rear view mirror 2 1 2 For installation reverse the removal procedure 26 Nm 2 6 mSkg 10 Nm 1 0 mSkg 26 Nm 2 6 mSkg 23 Nm 2 3 mSkg ...

Page 221: ...o danger of it falling over 2 Remove Sthrottle cable housing 1 Sthrottle grip 2 While removing the throttle cable housing pull back the rubber cover 3 3 Remove Shandlebar switch left and right 4 Remvoe Supper handlebar holder 5 Remove Shandlebar grip 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar ...

Page 222: ...en a bent handle bar as this may dangerously weaken it 2 Install Shandlebar grip a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag Do not touch the handlebar grip until the rubber adhesive has fully dried ...

Page 223: ... all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position SThe upper handlebar holders should be installed with the arrow marks a facing for ward A SAlign the match marks b on the handlebar with the upper surface of the lower handlebar holders 3 Install Sthrottle grip Sthrottle cable housing Sthrottle cable Align the projection a on the throttle ca...

Page 224: ...hium soap based grease 7 Adjust Sclutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 X 15 mm 8 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 X 5 mm ...

Page 225: ...h lead coupler Cable guide Horn Brake hose bracket Steering stem nut Washer Upper bracket Lock washer Upper ling nut 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT FORK Refer to HANDLEBAR Disconnect 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg 7 Nm 0 7 mSkg 52 Nm 5 2 mSkg 15 Nm 1 5 mSkg EAS00676 STEERING HEAD ...

Page 226: ... Nm 5 2 mSkg 15 Nm 1 5 mSkg Order Job Part Q ty Remarks 10 11 12 13 14 15 16 17 18 Rubber washer Lower ring nut Lower bracket Bearing cover Bearing inner race Upper bearing Lower bearing Bearing outer race Dust seal 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure ...

Page 227: ... on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Remove Ssteering stem nut 3 Remove Supper ring nut Slower ring nut 1 with the special tool 2 Steering nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling ...

Page 228: ...he steer ing head pipe with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing races If the bearing race is not installed properly the steering head pipe could be damaged SAlways replace the bearing balls and bearing races as a set SWhenever the steering head is disassembled replace the dust seal 4 C...

Page 229: ...m soap based grease 2 Install Slower ring nut 1 Srubber washer 2 Supper ring nut 3 Slock washer 4 Refer to CHECKING THE STEERING HEAD in chapter 3 3 Install Supper bracket Ssteering stem nut Temporarily tighten the steering stem nut 4 Install Sfront fork legs Refer to INSTALLING THE FRONT FORK LEGS Temporarily tighten the upper and lower bracket pinch bolts ...

Page 230: ...Nut washer bolt Nut washer bolt Nut bolt Nut Rear shock absorber upper bracket Rear shock absorber Oil seal Bearing Collar Bearing 2 2 2 1 1 1 1 1 1 1 1 8 4 2 2 Remove the parts in the order listed Refer to SEAT in chapter 3 52 Nm 5 2 mSkg 44 Nm 4 4 mSkg 40 Nm 4 0 mSkg 49 Nm 4 9 mSkg 40 Nm 4 0 mSkg EAS00685 REAR SHOCK ABSORBER ASSEMBLY ...

Page 231: ...BSORBER ASSEMBLY CHAS 52 Nm 5 2 mSkg 44 Nm 4 4 mSkg 40 Nm 4 0 mSkg 49 Nm 4 9 mSkg 40 Nm 4 0 mSkg Order Job Part Q ty Remarks 11 12 13 Collar Connecting arm Relay arm 2 2 1 For installation reverse the removal procedure ...

Page 232: ...rear shock absorber or gas cylinder SDo not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure SDo not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REA...

Page 233: ... Disconnect Sbattery leads from the battery terminals First disconnect the negative battery lead then the positive battery lead 3 Remove Sbattery 4 Remove Sconnecting arm bolt 1 Srear shock absorber assembly lower bolt 2 While removing the rear shock absorber as sembly lower bolt hold the swingarm so that it does not drop down 5 Remove Srear shock absorber assembly upper bolt 1 Srear shock absorbe...

Page 234: ...ear Replace the rear shock ab sorber assembly Sgas cylinder Damage gas leaks Replace Sbushings Damage wear Replace Sdust seals Damage wear Replace Sbolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Sspacers Sbearings Recommended lubricant Molybdenum disulfide grease 2 Install Srear shock absorber upper bracket Srear shock absorber assembly SWhen insta...

Page 235: ... 5 2 mSkg CAUTION 3 Tighten Srear shock absorber assembly upper nut Srear shock absorber assembly lower nut 1 Sconnecting arm nut 2 Srear shock absorber upper bracket nut 4 Connect Sbattery leads to the battery terminals First connect the positive battery lead then the negative battery lead ...

Page 236: ...eel Rear shock absorber assembly Pivot shaft nut washer Pivot shaft Swingarm Dust cover 1 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Refer to REAR SHOCK ABSORBER ASSEMBLY 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg 95 Nm 9 5 mSkg 5 Nm 0 5 mSkg EAS00700 SWINGARM AND DRIVE CHAIN ...

Page 237: ... 7 mSkg 95 Nm 9 5 mSkg 5 Nm 0 5 mSkg Order Job Part Q ty Remarks 5 6 7 8 9 10 11 12 13 Bearing Collar Oil seal Washer Spacer Rear fender Chain protector Pivot shaft adjusting bolt Drive chain 2 1 1 1 1 1 1 1 1 For installation reverse the removal procedure ...

Page 238: ... swingarm so that it does not drop down 3 Measure Sswingarm side play Sswingarm vertical movement a Measure the tightening torque of the pivot shaft nut Pivot shaft nut 95 Nm 9 5 mSkg b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of th...

Page 239: ...lace the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sswingarm 3 Remove Sdrive chain EAS00707 CHECKING THE SWINGARM 1 Check Sswingarm Bends cracks damage Replace 2 Check Spivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash Spivot shaft Sdust covers Sspacer Swashers Sbearings Recommended cleaning solv...

Page 240: ...NG THE CONECTING ARM AND RELAY ARMS 1 Check Sconnecting arms 1 Srelay arm 2 Damage wear Replace 2 Check Sbearings 3 Soil seals 4 Damage pitting Replace 3 Check Sspacers 5 Damage scratches Replace ASSEMBLING THE SWINGARM 1 Install Sbearings Soil seals New a Install the new bearings and oil seals in the reverse order of disassembly Use a socket that matches the diameter of the bearing outer race and...

Page 241: ...ffness Clean and lubricate or replace 3 Clean Sdrive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plate Never use high pressure water or air steam gasoline certain solvents e g ...

Page 242: ...procket as a set Cracks Replace the drive chain drive sprocket and rear wheel sprocket as a set and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate Sdrive chain Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains 6 Check Sdrive sprocket Srear wheel sprocket More than 1 4 tooth a wear Replace the driv...

Page 243: ...or O ring chains 3 Install Sdrive chain to the swingarm 4 Install Sswingarm to the frame 5 Install Srelay arm 1 Sconnecting arms 2 Install the connecting arm front bolt 3 from the left 6 Install Spivot shaft adjusting bolt Sswingarm Spivot shaft Swasher Spivot shaft nut Use the pivot shaft wrench 1 to tighten the pivot adjust bolt to finger tightness Pivot shaft wrench 90890 01455 7 Install Srear ...

Page 244: ...ket nut 9 Bend the lock washer tab a along a flat side of the nut 10 Adjust Sdrive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 50 X 60 mm A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swin garm or cause an accident Therefore keep the drive chain slack within the specified limi...

Page 245: ......

Page 246: ... 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 26 CHECKING THE VALVE SPRINGS 5 28 CHECKING THE VALVE LIFTERS 5 29 INSTALLING THE VALVES 5 29 CYLINDER AND PISTONS 5 32 REMOVING THE CYLINDER AND PISTONS 5 33 CHECKING THE CYLINDER AND PISTONS 5 34 CHECKING THE PISTON RINGS 5 36 CHECKING THE PISTON PINS 5 37 INSTALLING TH...

Page 247: ... OIL PAN AND OIL PUMP 5 60 OIL PUMP COVER AND OIL PUMP DRIVEN GEAR 5 60 OIL PUMP 5 61 OIL HOSE AND OIL TANK 5 63 OIL PAN 5 64 CHECKING THE OIL PUMP 5 65 REMOVING THE OIL PAN 5 65 CHECKING THE RELIEF VALVE 5 66 CHECKING THE OIL DELIVERY PIPES 5 66 CHECKING THE OIL STRAINER 5 66 CHECKING THE OIL NOZZLES 5 66 ASSEMBLING THE OIL PUMP 5 67 INSTALLING THE OIL PUMP 5 67 INSTALLING THE OIL STRAINER 5 68 I...

Page 248: ...E CRANKCASE 5 83 INSTALLING THE BALANCER SHAFT 5 85 TRANSMISSION 5 87 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 87 REMOVING THE TRANSMISSION 5 92 CHECKING THE SHIFT FORKS 5 92 CHECKING THE SHIFT DRUM ASSEMBLY 5 93 CHECKING THE TRANSMISSION 5 93 INSTALLING THE TRANSMISSION 5 94 ...

Page 249: ...ENG ...

Page 250: ...n the order listed Disconnect For installation reverse the removal procedure First disconnect the negative battery lead and then the positive battery lead For connecting reverse the disconnection procedure CAUTION 24 Nm 2 4 mSkg 20 Nm 2 0 mSkg 10 Nm 1 0 mSkg 24 Nm 2 4 mSkg ENGINE ENG EAS00188 ENGINE ENGINE EXHAUST PIPES Anti seize lubricart high temparature grade ...

Page 251: ...et Drive sprocket cover Shift arm Shift rod Cover 1 Speed sensor rotor Cover 2 Nut lock washer Drive sprocket 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 12 NM 1 2 mSkg 85 Nm 8 5 mSkg 10 Nm 1 0 mSkg 20 Nm 2 0 mSkg DRIVE SPROCKET ...

Page 252: ...ttery positive lead Starter motor lead 1 1 1 Remove the parts in the order listed Refer to FUEL INJECTION SYSTEM in chapter 7 Refer to RADIATOR in chapter 6 Disconnect First disconnect the negative battery lead and then the positive battery lead For connecting reverse the disconnec tion procedure CAUTION Refer to SEAT FUEL TANK AIR FILTER CASE in chapter 3 EAS00190 LEADS AND HOSES ...

Page 253: ...t Q ty Remarks 4 5 6 7 Neutral switch lead coupler Generator lead coupler Throttle body sub wire harness coupler Speed sensor lead 1 1 2 1 Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure ...

Page 254: ...Collar Adjusting bolt Engine bracket Engine 2 1 1 2 2 1 1 Remove the parts in the order listed Place a suitable stand under the frame and engine Refer to STARTER MOTOR in chapter 8 Refer to INSTALLING THE ENGINE For installation reverse the removal procedure NOTE 55 Nm 5 5 mSkg 26 Nm 2 6 mSkg 45 Nm 4 5 mSkg 7 Nm 0 7 mSkg 26 Nm 2 6 mSkg 45 Nm 4 5 mSkg 30 Nm 3 0 mSkg EAS00191 ENGINE ...

Page 255: ...nch bolts 6 Sengine bracket bolts 7 SLubricate the rear mounting bolt threads with lithium soap base grease SDo not fully tighten the bolts 2 Tighten Sadjusting bolt 2 Sengine mounting nut rear upper 4 Sengine mounting nut rear lower 3 Sengine mounting bolts front 5 Spinch bolts 6 Sengine bracket bolts 7 STighten the adjusting bolt 2 to specification with a pivot shaft wrench 8 Pivot shaft wrench ...

Page 256: ...der head cover Cylinder head gascket 1 2 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to FRONT COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to AIR INDUCTION SYSTEM in chapter 7 For installation reverse the removal procedure Refer to RADIATOR in chapter 6 10 Nm 1 0 mSkg 4 Nm 0 4 mSkg 18 Nm 1 8 mSkg EAS00194 CAMSHAFT C...

Page 257: ...iming chain tensioner Gascket Camshaft cap Dowel pin Intake camshaft Exhaust camshaft Camshaft sprocket 2 1 1 4 8 1 1 2 Remove the parts in the order listed For installation reverse the removal procedure 10 Nm 1 0 mSkg 18 Nm 1 8 mSkg 10 Nm 1 0 mSkg 7 Nm 0 7 mSkg 24 Nm 2 4 mSkg EAS00196 CAMSHAFTS ...

Page 258: ...ston 1 is at TDC on the compres sion stroke align the T mark a with the sta tionary pointer b on the generator rotor TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Scamshaft sprocket bolts 1 4 Loosen Scap bolt 1 5 Remove Stiming chain tensioner 2 Sgasket 6 Remove Scamshaft caps 1 Sdowel pins For reference during installation put identifi...

Page 259: ...caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 7 Remove Sintake camshaft 1 Sexhaust camshaft 2 Stiming chain guide exhaust side To prevent the timing chain from falling into the crankcase fasten it with a wire 3 8 Remove Scamshaft sprocket ...

Page 260: ...eplace the cam shaft Camshaft lobe dimension limit Intake camshaft a 35 60 mm b 27 85 mm Exhaust camshaft a 35 60 mm b 27 85 mm 3 Measure Scamshaft runout Out of specification Replace Camshaft runout limit 0 03 mm 4 Measure Scamshaft journal to camshaft cap clear ance Out of specification Measure the camshaft journal diameter Camshaft journal to camshaft cap clearance 0 020 X 0 054 mm Limit 0 08 m...

Page 261: ... crisscross pattern working from the inner caps out SDo not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Camshaft cap bolt 10 Nm 1 0 mSkg d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Scamshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylinder head a...

Page 262: ...aft sprockets and timing chain guides 1 Check Scamshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 2 Check Stiming chain guide 1 exhaust side Stiming chain guide 2 top side Damage wear Replace the defective part s ...

Page 263: ...e timing chain tensioner housing by hand While pressing timing chain tensioner rod wind it clockwise with a thin screw driver 1 unitl it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner 3 Check Scap b...

Page 264: ...e camshaft face up 3 Install Sdowel pins Sexhaust camshaft caps SMake sure each camshaft cap is installed in its original place SMake sure the arrow mark a on each cam shaft cap points towards the right side of the engine 4 Install Scamshaft cap bolts Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out SLubricate the camshaft cap bolts with the engi...

Page 265: ... tightened SMake sure the punch mark on the camshaft face up SWhen installing the intake camshaft be sure to keep the timing chain as tight as possible be tween the exhaust camshaft sprocket and in take camshaft sprocket 7 Install Sdowel pins Sintake camshaft caps SMake sure each camshaft cap is installed in its original place SMake sure the arrow mark a on each cam shaft cap points towards the ri...

Page 266: ...lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful ly clockwise with a thin screwdriver 1 b With the timing chain tensioner rod turned all the way into the timing chain tensioner hous ing with the thin screwdriver still installed install the gasket and the timing chain ten sioner 2 onto the cylinder block Always use a new gasket c Tighten the timing chain tensioner...

Page 267: ...Make sure the punch marks on the cam shafts are aligned with the embossed marks d on the camshaft cap Out of alignment Adjust Refer to the installation steps above 12 Tighten Scamshaft sprocket bolts 1 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 13 Measure Svalve clearance Out of specification Adj...

Page 268: ... Dowel pin Timing chain guide exhaust side Collar 1 1 2 1 2 Remove the parts in the order listed Refer to EXHAUST PIPES and DRIVE SPROCKET Refer to CAMSHAFT Refer to THROTTLE BODY in chapter 7 For installation reverse the removal procedure 10 Nm 1 0 mSkg 55 Nm 5 5 mSkg 55 Nm 5 5 mSkg 18 Nm 1 8 mSkg Initial 18 Nm 1 8 mSkg 2nd 150_ Final EAS00221 CYLINDER HEAD ...

Page 269: ...ng Sspark plug bore threads Svalve seats 2 Check Scylinder head Damage scratches Replace Scylinder head water jacket Mineral deposits rust Eliminate 3 Measure Scylinder head warpage Out of specification Resurface the cylin der head Maximum cylinder head warpage Less than 0 10 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceed...

Page 270: ...uts 1 X 6 to 18 Nm 1 8 mSkg with a torgue wrench SLoosen the nuts one by one following the tight ening order and then thighten them to 18 Nm 1 8 mSkg again SRetighten the nuts to 150_ with angle torgue gauge SUse an angle torgue gauge 1 and tighten at the correct angle SIf an angle torgue gauge is not available do not tighten at an angle because accurate tightening cannot be expected Thightening i...

Page 271: ...ings Valve lifter Valve pad Valve cotter Upper valve spring seat Valve spring Valve spring seat Valve stem seal Exhaust valve Intake valve center Intake valve left and right 10 10 20 10 10 10 10 4 2 4 Remove the parts in the order listed For installation reverse the removal procedure EAS00236 VALVES AND VALVE SPRINGS ...

Page 272: ...e position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check Svalve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 3 Remove Svalve co...

Page 273: ...39 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification Replace the valve guide Valve stem to valve guide clearance Intake 0 010 X 0 037 mm Limit 0 08 mm Exhaust 0 025 X 0 052 mm Limit 0 1 m...

Page 274: ...Valve guide installer 5 5 mm 90890 04015 Valve guide reamer 5 5 mm 90890 01196 3 Eliminate Scarbon deposits from the valve face and valve seat 4 Check Svalve face Pitting wear Grind the valve face Svalve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Svalve margin thickness a Out of specification Replace the valve Valve margin thickness 0 8 X...

Page 275: ...ve seat width Intake 0 9 X 1 1 mm Limit 1 6 mm Exhaust 0 9 X 1 1 mm Limit 1 6 mm a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width Where the valve seat and valve face contacted one another the blueing will have been re move...

Page 276: ...est lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder hea...

Page 277: ... free length Intake and exhaust valve spring 37 3 mm Limit 35 4 mm 2 Measure Scompressed valve spring force a Out of specification Replace the valve spring b Installed length Compressed valve spring force installed Intake and exhaust valve spring 98 1 X 113 8 N 10 0 X 11 6 kgf at 30 4 mm 3 Measure Svalve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake and exhau...

Page 278: ...linder head EAS00247 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Svalve stem end with an oil stone 2 Lubricate Svalve stem 1 Svalve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install Svalve 1 Slower spring seat 2 Svalve stem seal 3 Svalve spring 4 Supper spring seat 5 into the cylinder h...

Page 279: ...the larger pitch a facing up b Smaller pitch 4 Install Svalve cotters 1 Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 04108 5 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a soft face hammer Hitti...

Page 280: ...t Molybdenum disulfide oil Svalve lifter with the recommended lubricant Recommended lubricant Engien oil 7 Install Svalve pad Svalve lifter SThe valve lifter must move smoothly when ro tated with a finger SEach valve lifter and valve pad must be rein stalled in its original position ...

Page 281: ...emoving the cylinder and pistons Cylinder head Cylinder Cylinder gascket Circlip Piston pin piston Piston ring set Dowel pin 1 1 4 2 2 2 2 Remove the parts in the order listed Refer to CYLINDER HEAD For installation reverse the removal procedure EAS00252 CYLINDER AND PISTONS ...

Page 282: ...nt the piston pin clip from falling into the crank case SFor reference during installation put an identi fication mark on each piston crown SBefore removing the piston pin 2 deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 2 Remov...

Page 283: ...find the average of the measure ments Cylinder bore C 92 00 X 92 01 mm Taper limit T 0 05 mm Out of round R 0 05 mm C maximum of D1 X D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 mini mum of D2 D4 or D6 b If out of specification replace the cylinder and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 5 mm from the bottom edge of...

Page 284: ...5 35 CYLINDER AND PISTONS ENG Piston to cylinder clearance 0 025 X 0 050 mm Limit 0 11 mm f If out of specification replace the cylinder and the piston and piston rings as a set ...

Page 285: ...ide clearance Top ring 0 03 X 0 07 mm Limit 0 12 mm 2nd ring 0 02 X 0 06 mm Limit 0 12 mm 2 Install Spiston ring into the cylinder Level the piston ring into the cylinder with the piston crown a 5 mm 3 Measure Spiston ring end gap Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston ...

Page 286: ...the piston pin Piston pin outside diameter 20 991 X 21 000 mm Limit 20 971 mm 3 Measure Spiston pin bore diameter in the piston b Out of specification Replace the piston Piston pin bore diameter in the piston 21 004 X 21 015 mm Limit 21 045 mm 4 Calculate Spiston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston clearance Piston p...

Page 287: ...n 1 Spiston pin 2 Spiston pin clip New 3 SApply engine oil onto the piston pin SMake sure the arrow mark a on the piston faces towards the exhaust side of the engine SBefore installing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank case SReinstall each piston into its original cylinder numbering order starting from the le...

Page 288: ...ing b Lower oil ring rail c Upper oil ring rail d 2nd ring A Intake side 6 Install Scylinder SWhile compressing the piston rings with one hand install the cylinder with the other hand SPass the timing chain and timing chain guide exhaust side through the timing chain cavity ...

Page 289: ...utch cable Clutch cable stay Clutch cover Gascket Dowel pin 1 1 1 1 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 For installation reverse the removal procedure NOTE Loosen the bolts in a crisscross pattern 10 Nm 1 0 mSkg EAS00273 CLUTCH CLUTCH COVER ...

Page 290: ... 7 Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing Washer 2 1 1 1 1 2 2 Remove the parts in the order listed For installation reverse the removal procedure CLUTCH ENG EB405010 PULL LEVER SHAFT ...

Page 291: ...ving the clutch Clutch spring Pressure plate Pull rod Friction plate 1 Clutch plate Friction plate 2 Nut Lock washer Clutch boss Thrust plate Bearing Spacer Clutch housing 6 1 1 2 8 7 1 1 1 1 1 1 1 Remove the parts in the order listed 70 Nm 7 0 mSkg 8 Nm 0 8 mSkg EAS00274 CLUTCH ...

Page 292: ...5 43 CLUTCH ENG Order Job Part Q ty Remarks 14 15 Thrust plate 1 Thrust plate 2 1 1 For installation reverse the removal procedure 70 Nm 7 0 mSkg 8 Nm 0 8 mSkg ...

Page 293: ...oss 3 4 Remove Sspacer 1 Sbearing 2 Insert two 6 mm bolts 3 into the spacer and then remove the spacer by pulling on the bolts EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Sfriction plate Damage wear Replace the friction plates as a set 2 Measure Sfriction plate thickness Out of specification Replace the friction plates as a set Measu...

Page 294: ...lowing table Clutch plate 1 Part No Thickness 168 16325 00 1 6 mm 3J2 16324 00 2 0 mm STD 168 16324 00 2 3 mm Clutch plate 2 Part No Thickness 3J2 16324 00 2 0 mm STD 168 16324 00 2 3 mm When adjusting the clutch assembly width by replacing the clutch plate s be sure to replace the clutch plate 1 first After replacing the clutch plate 1 if specifications cannot be met replace the clutch plate 2 ...

Page 295: ...e and thickness gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit Less than 0 1 mm EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Sclutch spring Damage Replace the clutch springs as a set 2 Measure Sclutch spring free length a Out of specification Replace the clutch springs as a set Clutch spring fr...

Page 296: ...dogs will cause er ratic clutch operation 2 Check Sbearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check Sclutch boss splines Damage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check Spressure plate 1 Cracks damage Replace Sbearing 2 Damage wear Rep...

Page 297: ...the pull rod and pull lever shaft pinion gear as a set 2 Check Spull rod bearing Damage wear Replace EAS00292 CHECKING THE PRIMARY DRIVE 1 Check Sprimary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Re place the primary drive and primary driven gears as a set ...

Page 298: ...end the lock washer tab along a flat side of the nut 4 Lubricate Sfriction plates Sclutch plates with the recommended lubricant Recommended lubricant Engine oil 5 Install Sfriction plates Sclutch plates First install a friction plate and then alternate between a clutch plate and a friction plate 6 Measure Sassembly width Out of specification Adjust Refer to CHECKING THE FRICTION PLATE 7 Install Sp...

Page 299: ... the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod groove c and pull lever shaft groove d are engaged STighten the clutch cover bolts in stages and in a crisscross pattern 10 Install Swasher 1 Spull lever spring 2 Spull lever 3 Swasher 4 Scirclip New 5 Align the punch mark a in the pull leve...

Page 300: ...ed sensor rotor Cover 2 Generator rotor cover Gasket Dowel pin Drive chain slider 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure Loosen the bolts in stages and in a crisscross pattern NOTE 10 Nm 1 0 mSkg 20 Nm 2 0 mSkg 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER ...

Page 301: ...ft arm Circlip Washer Shift shaft Shift shaft spring Stopper lever Bearing retainer Stopper lever spring 2 2 1 1 1 1 1 Remove the parts in the order listed Refer to CLUTCH Refer to GENERATOR ROTOR COVER For installation reverse the removal procedure 10 Nm 1 0 mSkg 12 Nm 1 2 mSkg EAS00327 SHIFT SHAFT AND STOPPER LEVER ...

Page 302: ...er turns roughly Replace the stopper lever EAS00331 INSTALLING THE SHIFT SHAFT 1 Install Sstopper lever 1 Sstopper lever spring 2 Sretainer 3 SHook the ends of the stopper lever spring onto the stopper lever and the crankcase boss SMesh the stopper lever with the shift drum seg ment assembly 2 Install Swasher Sshift shaft 1 SLubricate the oil seal lips with lithium soap based grease SHook the end ...

Page 303: ...r Stator coil coupler Pickup coil coupler Stator coil Pickup coil Generator cover Gasket Dowel pin 1 1 1 1 1 2 Remove the parts in the order listed Drain Refer to GENERATOR ROTOR COVER Disconnect For installation reverse the removal procedure 4 Nm 0 4 mSkg 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY ...

Page 304: ...rotor Idle gear shaft Starter motor idle gear Starter clutch Washer Woodruff key Starter clutch gear 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 10 Nm 1 0 mSkg 130 Nm 13 0 mSkg STARTER CLUTCH AND GENERATOR ENG EAS00343 STARTER CLUTCH AND GENERATOR ROTOR ...

Page 305: ...lder to touch the projection on the generator rotor Sheave holder 90890 01701 2 Remove Sgenerator rotor 1 with the flywheel puller 2 and flywheel pull er attachment 3 Swoodruff key To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set s center bolt and the crank shaft Make sure the flywheel puller is centered over the generator rotor Flywheel pulle...

Page 306: ...der to touch the projection on the generator rotor Sheave holder 90890 01701 EAS00351 CHECKING THE STARTER CLUTCH 1 Check Sstarter clutch rollers 1 Damage wear Replace 2 Check Sstarter clutch idle gear 1 Sstarter clutch gear 2 Burrs chips roughness wear Replace the defective part s 3 Check Sstarter clutch gear s contacting surfaces a Damage pitting wear Replace the starter clutch gear 4 Check Ssta...

Page 307: ...hould engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS00352 CHECKING THE GENERATOR SHAFT 1 Check Sgenerator shaft Damage wear Replace the generator shaft Soil passages Dirt obstruction Wash the generator shaft and then blow out the oil ...

Page 308: ...0 01701 EAS00354 INSTALLING THE GENERATOR 1 Install Swoodruff key Sgenerator rotor 1 Swasher 2 Sgenerator rotor bolt 3 SClean the tapered portion of the crankshaft and the generator rotor hub SWhen installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft 2 Tighten Sgenerator rotor bolt 1 SWhile holding the generator rotor 2 with the sheave holde...

Page 309: ...l pipe O ring Oil pump cover Gascket Dowel pin Collar Gascket Circlip Oil pump driver gear 1 1 1 1 2 1 1 2 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 For installation reverse the removal procedure 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00357 OIL PAN AND OIL PUMP OIL PUMP COVER AND OIL PUMP DRIVEN GEAR ...

Page 310: ... Part Q ty Remarks 1 2 3 4 5 Removing the oil pump Scavenge pump Gascket Dowel pin Feed pump Gascket 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 6 Nm 0 6 mSkg 6 Nm 0 6 mSkg EAS00359 OIL PUMP ...

Page 311: ...t Q ty Remarks Disassembling the oil pump Oil pump cover Oil pump housing Inner rotor Outer rotor Rotor shaft Dowel pin Stay 2 2 2 2 2 4 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 EAS00360 ...

Page 312: ...4 5 6 7 Removing the oil hose and oil tank Oil hose 1 O ring Oil tank Union bolt Oil pipe Oil hose 2 Oil level switch coupler 1 1 1 2 1 1 1 Remove the parts in the order listed Disconnect For installation reverse the removal procedure EAS00358 OIL HOSE AND OIL TANK ...

Page 313: ...r Oil pan Gascket Dowel pin O ring collar Oil strainer cover filter bracket Relief valve 1 1 1 1 1 1 2 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to OIL HOSE For installation reverse the removal procedure NOTE Install the oil filter with the projection towards the oil filter cover 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00356 OIL PAN ...

Page 314: ...ecification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 00 X 0 12 mm Outer rotor to oil pump housing clearance 0 03 X 0 08 mm Oil pump housing to inner rotor and outer rotor clearance 0 03 X 0 08 mm 3 Check Soil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS00362 REMOVING THE OIL PAN 1 Remove...

Page 315: ...il delivery pipes Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check Soil strainer 1 Damage Replace Contaminants Clean with solvent EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Soil nozzle Scheck ball Damage wear Replace the oil nozzle SO ring Damage wear Replace Soil nozzle passage Obs...

Page 316: ...tall Soil pump shaft 1 to the oil pump cover 2 Spin 3 Sinner rotor 4 Souter rotor 5 Spin 6 Soil pump housing 7 When installing the inner rotor align the pin 3 in the oil pump shaft with the groove in the inner ro tor 4 3 Check Soil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install Soil pump 1 After tightening the bolts make sure the oil pump turns smoothly 2 ...

Page 317: ...r SO ring Soil strainer 1 The mark a on the oil strainer housing must point towards the front of the engine EAS00380 INSTALLING THE OIL PAN 1 Install Srelief valve 1 2 Install Sdowel pins Sgasket New Soil pan 1 Sengine oil drain bolt Always use new copper washers Tighten the oil pan bolts in stages and in a criss cross pattern 3 Install Soil tank ...

Page 318: ...n Crankcase upper cover Gascket Dowel pin Balancer shaft retainer Rear balancer holder Dowel pin Rear balancer shaft O ring 1 1 2 2 1 2 1 1 Remove the parts in the order listed Refer to ENGINE Refer to OIL TANK Refer to OIL PAN 10 Nm 1 0 mSkg 12 Nm 1 2 mSkg 12 Nm 1 2 mSkg 10 Nm 1 0 mSkg CRANKSHAFT BALANCER SHAFT ...

Page 319: ... 10 11 12 Rear balancer weight Front balancer holder Dowel pin Front balancer shaft O ring Front balancer weight Water pump drive gear 1 1 2 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 12 Nm 1 2 mSkg 12 Nm 1 2 mSkg 10 Nm 1 0 mSkg ...

Page 320: ...hain guide intake Lower crankcase Dowel pin Crankshaft assembly Main journal bealing Upper crankcase 1 1 1 1 1 1 1 6 1 Remove the parts in the order listed Refer to BALANCER Refer to WATER PUMP in chapter 6 For installation reverse the removal procedure 24 Nm 2 4 mSkg 12 Nm 1 2 mSkg 10 Nm 1 0 mSkg Initial 20 Nm 2 0 mSkg 2nd 55_ Final EAS00381 CRANKSHAFT ASSEMBLY ...

Page 321: ... 2 3 4 5 Removing the connecting rod Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod bearing 4 4 2 2 4 Remove the parts in the order listed For installation reverse the removal procedure 62 Nm 6 2 mSkg EAS00382 CONNECTING ROD ...

Page 322: ...case tightening sequence A Upper crankcase B Lower crankcase 3 Place the engine upside down 4 Remove Slower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly M6 70 mm bolts 1 2 8 X 14 16 18 19 M8 75 mm bolts 3 X 7 15 1...

Page 323: ...ING THE CONNECTING RODS The following procedure applies to all of the connecting rods 1 Remove Sconnecting rods 1 Sconnecting rod caps 2 Sbig end bearings 3 Identify the position of each big end bearing so that it can be reinstalled in its original place CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Stiming chain Damage stiffness Replace the timing chain and camshaft sprockets as a set ...

Page 324: ...al bearing clearance 0 020 X 0 038 mm Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crankshaft journals and bearing portions of the crankcase b Place the upper crankcas...

Page 325: ...e Crankcase bolt Initial 10 Nm 1 0 mSkg 2nd 20 Nm 2 0 mSkg Final 55_ SUse an angle torgue gauge 1 and tighten at the correct angle SIf an angle torque gauge is not available do not tighten at an angle because accurate tightening cannot be expected Thightening in this case should be con trolled by torgue and final tightening should be to 41 Nm 4 1 mSkg Lubricate the crankcase bolt threads with en g...

Page 326: ...bers are 6 and 2 respec tively then the bearing size for J1 is J1 crankcase J1 crankshaft web 6 2 4 green CRANKSHAFT JOURNAL BEARING COLOR CODE 1 blue 2 black 3 brown 4 green 5 yellow 6 pink 7 red 5 Measure Scrankshaft pin to big end bearing clear ance Out of specification Replace the big end bearings Crankshaft pin to big end bearing clearance 0 036 X 0 060 mm The following procedure applies to a...

Page 327: ...ke sure the Y mark c on the connecting rod faces towards the left side of the crank shaft SMake sure the characters on both the connect ing rod and connecting rod cap are aligned e Tighten the connecting rod nuts SWhen tightening the connecting rod nuts be sure to use an F type torque wrench SWithout pausing tighten the connecting rod nuts to the specified torque Apply con tinuous torque between 5...

Page 328: ...ation For example if the connecting rod P1 and the crankshaft web P1 numbers are 4 and 1 re spectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 4 1 3 brown BIG END BEARING COLOR CODE 1 blue 2 black 3 brown 4 green EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3...

Page 329: ... Sconnecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil 3 Install Sbig end bearings 1 Sconnecting rods 2 Sconnecting rod caps 3 onto the crankshaft pins SAlign the projections on the big end bearings with the notches in the connecting rods and connecting rod caps SBe sure to reinstall each big end bearing in its original place SMake sure the Y marks a on the ...

Page 330: ...e an F type torque wrench SWithout pausing tighten the connecting rod nuts to the specified torque Apply con tinuous torque between 52 and 62 Nm 5 2 and 6 2 mSkg Once you reach 52 Nm 5 2 mSkg DO NOT STOP TIGHTENING until the specified torque is reached If the tighten ing is interrupted between 52 and 62 Nm 5 2 and 6 2 mSkg loosen the connecting rod nut to less than 52 Nm 5 2 mSkg and start again ...

Page 331: ...nkshaft jour nal upper bearings 1 with the notches b in the upper crankcase SBe sure to install each crankshaft journal up per bearing in its original place 2 Install Stiming chain 1 onto the crankshaft sprocket Scrankshaft assembly 2 SPass the timing chain through the timing chain cavity STo prevent the timing chain from falling into the crankcase fasten it with a wire ...

Page 332: ... into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings 3 Install Sdowel pin 1 Soil jet nozzle 4 Install Scrankshaft journal lower bearings into the lower crankcase SAlign the projections a on the crankshaft jour nal lower bearings 1 with the notches b in the lower crankcase SInstall each crankshaft journal lower...

Page 333: ...tighten at an angle because accurate tightening cannot be expected Thightening in this case should be con trolled by torgue and final tightening should be to 41 Nm 4 1 mSkg Scrankcase bolts M6 Scrankcase bolts M8 SLubricate the bolt threads 1 X 28 with en gine oil STighten the bolts in the tightening sequence cast on the crankcase SInstall a copper washer on bolts 16 22 24 26 A Upper crankcase B L...

Page 334: ... until the keyway a on the crankshaft is aligned with the mark b on the crankcase b While holding the crankshaft install the front balancer shaft weight and align the mark c on the front balancer shaft gear with the mark d on the crankcase c Install the front balancer shaft 2 Install Sdowel pins Sfront balancer holder 1 3 Install Srear balancer shaft weight 1 Srear balancer shaft 2 SO ring New 3 ...

Page 335: ...nkshaft is aligned with the mark b on the crankcase b While holding the crankshaft install the rear balancer shaft weight and align the mark c on the rear balancer shaft gear with the mark d on the crankcase c Install the rear balancer shaft 4 Install Sdowel pins Srear balancer holder 1 ...

Page 336: ...and shift forks Engine Cover plate Collar Oil seal Bearing Circrip Main axle assembly Shift fork R Shift fork L Shift fork guide bar Shift fork C 1 1 1 4 1 1 1 1 2 1 Remove the parts in the order listed Refer to ENGINE 12 Nm 1 2 mSkg 10 Nm 1 0 mSkg EAS00419 TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS ...

Page 337: ...5 88 TRANSMISSION ENG Order Job Part Q ty Remarks 11 12 13 Shift drum Bearing housing Drive axle assembly 1 1 1 For installation reverse the removal pro cedure 12 Nm 1 2 mSkg 10 Nm 1 0 mSkg ...

Page 338: ...xle assembly 2nd pinion gear Lock washer Lock washer retainer 6th pinion gear Collar Washer Circlip 3rd 4th pinion gear 5th pinion gear Main axle 1 1 1 1 2 2 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 ...

Page 339: ...arks Disassembling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Lock washer Lock washer retainer 4th wheel gear 1 1 4 1 3 4 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 ...

Page 340: ...5 91 TRANSMISSION ENG Order Job Part Q ty Remarks 6th wheel gear 2nd wheel gear Drive axle 1 1 1 For assembly reverse the disassembly procedure 13 12 11 ...

Page 341: ...t 90890 01083 Weight 90890 01084 2 Remove Smain axle assembly from the clutch side EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Sshift fork cam follower 1 Sshift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Sshift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a...

Page 342: ...m assembly Sshift drum segment 1 Damage wear Replace the shift drum as sembly Sshift drum bearing 2 Damage pitting Replace the shift drum assembly EAS00425 CHECKING THE TRANSMISSION 1 Measure Smain axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 08 mm 2 Measure Sdrive axle runout with a centering device and dial gauge 1 Out o...

Page 343: ...ansmission axle assemblies 5 Check Stransmission gear movement Rough movement Replace the defective part s 6 Check Scirclips Bends damage looseness Replace EAS00429 INSTALLING THE TRANSMISSION 1 Install Smain axle assembly 1 When installing the main axle assembly use a pin 2 to align the bearing housing bolt hole with the corresponding hole in the lower crankcase 2 Install Sbearing housing 1 After...

Page 344: ...e engine and be in the following sequence R C L SInstall the shift fork guide bars with the tapered end a facing towards the clutch 4 Install Sdrive axle assembly SThe drive axle bearing pin must face towards the front of the crankcase SMake sure the drive axle bearing circlips 1 are inserted into the grooves 2 in the upper crank case 5 Check Stransmission Rough movement Repair Oil each gear shaft...

Page 345: ......

Page 346: ...COOL 6 ...

Page 347: ...OR 6 3 THERMOSTAT 6 4 THERMOSTAT ASSEMBLY 6 4 CHECKING THE THERMOSTAT 6 6 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 348: ...COOL ...

Page 349: ...t hose Radiator inlet hose Radiator cover Radiator 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT COWLING Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Disconnect For installation reverse the removal procedure 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg 5 Nm 0 5 mSkg EAS00454 COOLING SYSTEM RADIATOR ...

Page 350: ...e Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 95 X 125 kPa 0 95 X 1 25 kg cm2 a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Radiator cap tester adapter 90890 01352 b Apply the specified pressure for ten seconds and make sure there is no drop in pressu...

Page 351: ...ng system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 to the radia tor Radiator cap tester 90890 01325 Radiator cap tester adapter 90890 01352 b Apply 100 kPa 1 0 kg cm2 of pressure c Measure the indicated pressure with the gauge 3 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 352: ...cket Thermo unit lead coupler Thermostat inlet hose Thermostat outlet hose Thermostat assembly 1 1 1 1 1 Remove the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Drain For installation reverse the removal procedure Disconnect 10 Nm 1 0 mSkg EAS00460 THERMOSTAT THERMOSTAT ASSEMBLY ...

Page 353: ...isassembling the thermostat assembly Thermo unit Thermostat cover O ring Thermostat Thermostat housing 1 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 18 Nm 1 8 mSkg 10 Nm 1 0 mSkg EAS00461 ...

Page 354: ... 1 Thermostat 2 Thermometer 3 Water 4 Container A Fully closed B Fully open If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Sthermostat housing cover 1 Sthermostat housing 2 Cracks damage Replace 3 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RA...

Page 355: ...handling the thermo unit Replace any part that was dropped or subjected to a strong impact EAS00467 INSTALLING THE THERMOSTAT AS SEMBLY 1 Install Sthermostat assembly Sbracket 2 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check Scooling system Leaks Repair or replace any faulty part 4 Measure Sradiator cap opening pressure...

Page 356: ...sing 1 1 4 1 1 Remove the parts in the order listed It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Drain Refer to CHANGING THE COOLANT in chapter 3 For installation reverse the removal procedure 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00468 WATER PUMP ...

Page 357: ...ter pump Water pump cover Circlip Impeller Water pump seal Bearing Oil seal Water pump housing Rubber damper holder Rubber damper O ring 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 EAS00469 ...

Page 358: ...e water pump housing 3 Water pump housing 3 Remove Srubber damper holder 1 Srubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00473 CHECKING THE WATER PUMP 1 Check Swater pump cover 1 Swater pump housing 2 Simpeller 3 Srubber damper 4 Srubber damper holder 5 Swater pump seal Soil seal Cracks damage wear Replace 2 Check Sbearing Rough movement ...

Page 359: ...water pump seal New 1 Never lubricate the water pump seal surface with oil or grease SInstall the water pump seal with the special tools SBefore installing the water pump seal apply Yamaha bond No 1215 2 to the water pump housing 3 Mechanical seal installer 4 90890 04078 Middle driven shaft bearing driver 5 90890 04058 Yamaha bond No 1215 90890 85505 A Push down 3 Install Srubber damper New 1 Srub...

Page 360: ...amper holder are flush with the impeller Impeller shaft tilt limit 0 15 mm 1 Straightedge 2 Impeller 5 Install Simpeller Scirclip New After installation check that the impeller shaft rotates smoothly 6 Install Swater pump cover EAS00477 INSTALLING THE WATER PUMP 1 Install SO ring New 1 Lubricate the O ring with a thin coat of lithium soap based grease 2 Install Swater pump assembly ...

Page 361: ......

Page 362: ...OTING DETAILS 7 11 THROTTLE BODY ASSEMBLY 7 25 CHECKING THE INJECTOR 7 28 CHECKING THE THROTTLE BODY 7 28 CHECKING THE PRESSURE REGULATOR 7 28 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 29 CHECKING THE THROTTLE BODY JOINTS 7 30 CHECKING THE SURGE TANK 7 30 CHECKING THE ACTUATOR 7 30 AIR INDUCTION SYSTEM 7 31 AIR INJECTION 7 31 AIR CUT OFF VALVE 7 31 AIR INDUCTION SYSTEM DIAGRAMS 7 3...

Page 363: ...FI ...

Page 364: ...sensor 12 Catalytic converter 13 Crankshaft position sensor 14 Coolant temperature sensor 15 Spark plug 16 Cylinder identification sensor 17 Pressure regulator 18 Battery 19 ECU 20 Atmospheric pressure sensor 21 Fuel injection system relay 22 Engine trouble warning light 23 Lean angle cut off switch 24 Air cut off valve 25 Fast idle plunger 26 Adjustable air intake duct 27 Intake Solenoid FUEL INJ...

Page 365: ...air pressure sensor 20 Atmospheric pressure sensor 21 Intake air temperature sensor 22 Coolant temperature sensor 23 Lean angle cut off switch 24 ECU 25 O2 sensor 26 Injector 1 27 Injector 2 28 Al system solenoid 29 Intake solenoid 32 Fuel pump 33 Throttle position sensor 46 Engine stop switch 57 Ignition fuse FUEL INJECTION SYSTEM FI EAS00814 CIRCUIT DIAGRAM ...

Page 366: ...ght SAfter the engine has been stopped digital numbers representing the self diagnostic fault codes ap pear on the clock LCD Once a self diagnostic fault code has been displayed it remains stored in the ECU memory until a deletion operation is performed Engine trouble warning light indication and FI system operating conditions Warning light indication ECU s operating condition FI operating conditi...

Page 367: ...cted due to the internal malfunction S Fixes the intake air pressure and atmospheric pressure to 760 mmHg Able Able 21 Coolant temperature sensor Coolant temperature sensor open or short circuit detected S Fixes the coolant temperature to 60_C Able Able 22 Intake temperature sensor Intake temperature sensor open or short circuit detected S Fixes the intake temperature to 20_C Able Able 23 Atmosphe...

Page 368: ...tatement method in the troubleshooting details Checking the meter display Check whether the self diagnostic fault code num ber is shown after turning the main switch OFF once and then turning it back ON Erasing the melfunction history Malfunction history will be stored even if the main switch is turned OFF To erase the malfunction his tory it is required to operate to erase the malfunc tion histor...

Page 369: ... button Decrease When the button is pressed for a long time the display changes automatically It stops when the button is released Monitoring the sensor output data and checking the activation of actuators Monitoring the sensor output data When the Diagnostic monitoring code is selected the output data is displayed on the meter Refer to the Sensor operation table to judge the sensor performance Ch...

Page 370: ...ttle position sensor S Malfunction in ECU S Improperly installed throttle position sensor 01 19 Open circuit in the input line from the sidestand switch to the ECU is detected when the start switch is pressed S Open or short circuit in wiring harness S Malfunction in ECU 20 20 Defective values are detected due to the internal malfunction of the intake air temperature sensor or the atonospheric pre...

Page 371: ... S Malfunction in the engine side of the neutral switch S Malfunction in ECU 21 43 The ECU is unable to monitor the battery voltage an open circuit in the monitor line to the ECU S Open circuit in wiring harness S Malfunction in ECU 44 An error is detected while reading or writing on EEPROM S Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memory 60 ...

Page 372: ...s 09 Fuel system voltage battery voltage Approximately 12 0 Compare with the actually measured battery voltage If the battery voltage is lower perform recharging 20 Sidestand switch Stand retracted Stand extended ON OFF Turn ON OFF the Sidestand switch 21 Neutral switch Neutral In gear ON OFF Perform the shift operation of transmission 60 E2PROM fault code display No fault Fault detected 00 01 or ...

Page 373: ...tem solenoid five times 49 Intake solenoid Actuates the intake solenoid for five times every second Illuminates the engine trouble warning light Actuators may operate once or twice immediately after the engine stopped or cranking was performed Check the operating sound of the intake solenoid five times 50 Fuel injection system relay Actuates the fuel injection system relay for five times every sec...

Page 374: ...talled state of cylinder identification sensor Check the installed area for looseness or pinching Reinstated by starting the A 2 Connected state of connector Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect...

Page 375: ...shaft position sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Fault code No 13 Symptom Intake air pressure sensor open or short circuit defected Diagnostic monitoring code No 03 Intake air pressure sensor Order Item components Check or maintenance job Restore method 1 Connected state of connector Intake air pressure sensor coupler Main wiring harness ECU coupler Sub wire h...

Page 376: ...or malfunction at Intermediate electrical potential Repair or replace the sensor hose Check and repair the connection Replace it if there is a malfunction Reinstated by starting the engine and operating it at idle 2 Connected state of connector Intake air pressure sensor coupler Main wiring harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of t...

Page 377: ...d out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open circuit output volt...

Page 378: ...hat may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely If the transmission is in gear it is reinstated by refracing the sidestand If h 2 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Between ECU and sidestand switch If the transmission is in neutral it is reinstated ...

Page 379: ...s a malfunction repair it and connect it securely Reinstated by cranking the engine A 2 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White Pink White Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue A 3 Defective intake air pressure sensor Execute the diagnostic moni...

Page 380: ...e diagnostic monitoring mode Code No 06 Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Fault code No 22 Symptom Open or short circuit detected from the intake air temperature sensor Diagnostic monitoring code No 05 Intake air temperature sensor Order Item components Check or maintenance job Restore method 1 Installed state of intake air temperature sensor Check the installed area...

Page 381: ...r to FUEL INJECTION SYSTEM in chapter 8 Fault code No 24 Symptom No normal signal is received from the O2 sensor Diagnostic monitoring code No Order Item components Check or maintenance job Restore method 1 Installed state of O2 sensor Check the installed area for looseness or pinching As the returning method start 2 Connected state of connector O2 sensor coupler Main wiring harness ECU coupler Su...

Page 382: ...lean angle cut off switch Execute the diagnostic monitoring mode Code No 08 Replace if defective OFF Fault code No 33 Symptom Malfunction detected in the primary wire of the ignition coil 1 Diagnostic monitoring code No 30 Ignition coil 1 Order Item components Check or maintenance job Restore method 1 Connected state of connector Ignition coil primary side coupler Orange Main wiring harness ECU co...

Page 383: ...agnostic monitoring mode Code No 31 Test the primary and secondary coils for continuity Replace if defective Refer to IGNITION SYSTEM in chapter 8 Fault code No 41 Symptom Open or short circuit detected in the lean angle cut off switch Diagnostic monitoring code No 08 Lean angle cut off switch Order Item components Check or maintenance job Restore method 1 Connected state of connector Lean angle c...

Page 384: ...at a 20 to 30 km h A 3 Gear for detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 A 4 Defective speed sensor Execute the diagnostic monitoring mode Code No 07 Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 B 1 Connected state of connector Neutral switch coupler Main wiring harness ECU coupler Check the coupler for any pins that may have pu...

Page 385: ...oring mode Code No 50 Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 If there is no malfunction with the fuel injection system relay replace the ECU Fault code No 44 Symptom Error is detected while reading or writing on EEPROM CO adjustment value Diagnostic monitoring code No 60 EEPROM improper cylinder indication Order Item components Check or maintenance job Restore method 1 Ma...

Page 386: ...k or maintenance job Restore method 1 Connected state of connector Main wiring harness ECU coupler Main wiring harness meter coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Reinstated automatically when it receives a normal signal 2 Malfunction in meter unit Replace the meter unit...

Page 387: ... 1 Connected state of connector Main wiring harness ECU coupler Main wiring harness meter coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Reinstated automatically when it receives a normal signal 2 Malfunction in meter unit Replace the meter unit 3 Malfunction in ECU Replace the E...

Page 388: ...idle plunger hose Throttle cable Throttle body sub wire harness coupler Fuel return hose 1 2 2 2 1 Remove the parts in the order listed Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect Disconnect Disconnect Refer to SEAT FUEL TANK AIR FILTER CASE in chapter 3 10 Nm 1 0 mSkg FUEL INJECTION SYSTEM FI THROTTLE BODY ASSEMBLY ...

Page 389: ...INJECTION SYSTEM FI Order Job Part Q ty Remarks 6 7 8 9 Fuel hose Vacuum hose Throttle body assembly Throttle body joint 1 1 1 2 Disconnect Disconnect For installation reverse the removal procedure 10 Nm 1 0 mSkg ...

Page 390: ...idle plunger Pressur regulator Intake air pressure sensor Fuel injection pipe Fuel distributor Injector Throttle body Sub wire harness 1 1 1 1 1 1 2 1 Disassemble the parts in the order listed For assembly reverse the removal procedure CAUTION The throttle bodies should not be disassembled unnecessarily 1 2 3 4 5 6 7 8 9 ...

Page 391: ...ECKING THE THROTTLE BODY 1 Check Sthrottle body Cracks damage Replace the throttle bo dies 2 Check Sfuel passages Obstruction Clean a Wash the throttle body in a petroleumbased solvent Do not use any caustic carburetor cleaning solution b Blow out all of passages with compressed air CHECKING THE PRESSURE REGULATOR 1 Check Spressure regulator Damage Replace ...

Page 392: ...er 4 onto the fuel hose Vacuum pressure pump gauge set 90890 06756 Pressure gauge 90890 03153 Adapter 90890 03176 e Install the fuel tank Refer to FUEL TANK in chapter 3 f Start the engine g Measure the fuel pressure Fuel pressure 294 kPa 2 94 kgf cm2 2 94 bar h Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vac uum pressure as described below The vacuum pres...

Page 393: ...fuel tank Refer to FUEL TANK in chapter 3 Sair filter case Refer to AIR FILTER CASE in chapter 3 2 Check Sthrottle body joint 1 Cracks damage Replace 3 Install Sair filter case Sfuel tank CHECKING THE SURGE TANK 1 Remove Sfuel tank Sair filter case 2 Check Ssurge tank Cracks damage Replace CHECKING THE ACTUATOR 1 Check Sactuator Cracks damage Replace ...

Page 394: ...unburned exhaust gases is approximately 600 to 700 _C EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant tempera ture is below the specified value t...

Page 395: ...7 32 AIR INDUCTION SYSTEM FI 1 Air cut off valve 2 Reed valve 3 Exhaust port 4 Air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 396: ...lve Seat Fuel tank Air filter case Air cut off valve Hose Reed valve cover Reed valve assembly Plate 1 2 1 2 2 Remove the parts in teh order listed For installation reverse the removal pro cedure Refer to SEAT FUEL TANK AIR FILTER CASE in chapter 3 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg AIR CUT OFF VALVE AND REED VALVE ...

Page 397: ...NDUCTION SYSTEM 1 Check Shoses Loose connection Connect properly Cracks damage Replace Spipes Cracks damage Replace 2 Check Ssteel reed Ssteel reed stopper Sreed valve seat Cracks damage Replace the reed valve 3 Check Sair cut off valve Cracks damage Replace ...

Page 398: ...ELEC 8 ...

Page 399: ...ING 8 10 ELECTRIC STARTING SYSTEM 8 14 CIRCUIT DIAGRAM 8 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 15 TROUBLESHOOTING 8 16 STARTER MOTOR 8 20 CHECKING THE STARTER MOTOR 8 22 ASSEMBLING THE STARTER MOTOR 8 24 CHARGING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 26 LIGHTING SYSTEM 8 28 CIRCUIT DIAGRAM 8 28 TROUBLESHOOTING 8 29 CHECKING THE LIGHTING SYSTEM 8 31 SIGNALING SYSTEM 8 34 CIRCU...

Page 400: ...ELEC FUEL INJECTION SYSTEM 8 49 CIRCUIT DIAGRAM 8 49 TROUBLESHOOTING 8 50 CHECKING THE FUEL PUMP 8 56 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 8 57 ...

Page 401: ...motor 13 Horn 1 Wire harness 2 Ignition coil 3 Front brake light switch 4 Clutch switch 5 Starter relay 6 Fuse box 7 Battery 8 Neutral switch 9 Sidestand switch 10 Rear brake light switch 11 Oil level switch EAS00729 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 402: ...r 4 Intake air pressure sensor 5 Lean angle cut off switch 6 Turn signal relay 7 Fuel injection system relay 8 Radiator fan motor relay 9 Starting circuit cut off relay 10 Speed sensor 11 O2 sensor 12 Crankshaft position sensor 13 Cylinder identification sensor 14 ECU ELECTRICAL COMPONENTS ELEC ...

Page 403: ...to 0 and to the Ω 1 range SWhen checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a...

Page 404: ...itch 12 Neutral switch 13 Rear brake light switch 14 Fuses 15 Sidestand switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 405: ...lustration on the left SBulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The ma jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise SBulbs C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise SB...

Page 406: ...life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check Sbulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03132 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termin...

Page 407: ...t tester No continuity Replace Pocket tester 90890 03132 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb so...

Page 408: ... jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown SA wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn SThis check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity c When the jumper leads are connected to the terminals the respective LED s...

Page 409: ...in fuse 5 Battery 9 Main switch 13 Starting circuit cut off relay 14 Sidestand switch 23 Lean angle cut off switch 24 ECU 30 Ignition coil 31 Spark plug 33 Throttle position sensor 46 Engine stop switch 57 Ignition fuse EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 410: ...tion Re gap or replace the spark plug IGNITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 Main and ignition fuses 2 Battery 3 Spark plugs 4 Igni...

Page 411: ...tance The following procedure applies to all of the spark plug caps SRemove the spark plug cap from the spark plug lead SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20_C SIs the spark plug cap OK Replace the spark plug cap EAS00747 6 Ignition coil resistance The following procedure applies to all of the ign...

Page 412: ...itch SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES NO Replace the main switch EAS00750 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES NO Replace the right handlebar switch EAS00752 9 Sidestand switch SCheck the sidestand switch for continuity Refer to CHECKING THE S...

Page 413: ...conti nuity 2 1 1 2 EAS00754 12 Wiring SCheck the entire ignition system s wiring Refer to CIRCUIT DIAGRAM SIs the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition system s wiring Replace the ignitor unit EAS00753 10 Crankshaft position sensor rasistance SDisconnect the crankshaft position sensor coupler from the wire harness SConnect ...

Page 414: ...tery 7 Starter relay 8 Starter motor 9 Main switch 11 Diode 13 Starting circuit cut off relay 14 Sidestand switch 15 Neutral switch 46 Engine stop switch 47 Start switch 54 Clutch switch 57 Ignition fuse EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 415: ... the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND I...

Page 416: ...flammable is in the vicinity SDoes the starter motor turn WARNING 1 2 3 EAS00758 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00738 EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 Bat...

Page 417: ... blue white Tester negative prove black 3 4 5 Starting circuit cut off relay diode SDisconnect the starting circuit cut off relay from the wire harness SConnect the pocket tester Ω 1 to the starting circuit cut off relay terminals as shown SMeasure the starting circuit cut off relay for continuity as follows Tester positive probe blue green Tester negative probe blue yellow 4 3 Tester positive pro...

Page 418: ...S NO Replace the main switch EAS00750 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES NO Replace the right handlebar switch EAS00751 9 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK YES NO Replace the neutral switch EAS00752 10 Sidestand switch SCheck...

Page 419: ...the start switch OK YES NO Replace the right handlebar switch EAS00764 13 Wiring SCheck the entire starting system s wiring Refer to CIRCUIT DIAGRAM SIs the starting system s wiring properly con nected and without defects YES NO Properly connect or repair the starting system s wiring EAS00766 The starting system circuit is OK ...

Page 420: ...3 Removing the starter motor Exhaust pipe Starter motor lead Starter motor O ring 1 1 1 Remove the parts in the order listed Disconnect For installation reverse the removal procedure 10Nm 1 0 mSkg STARTER MOTOR ELEC EAS00767 STARTER MOTOR ...

Page 421: ...asher kit Rear bracket Washer kit Brush holder Brush Armature coil O ring Starter motor yoke Seal Bearing 1 1 1 1 1 2 1 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 11 10Nm 1 0 mSkg STARTER MOTOR ELEC EAS00768 ...

Page 422: ...rcut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resist...

Page 423: ...r 5 Measure Sbrush length a Out of specification Replace the brushes as a set Brush length wear limit 5 mm 6 Measure Sbrush spring force Out of specification Replace the brush springs as a set Brush spring force 8 82 N 882 gf 7 Check Sgear teeth Damage wear Replace the gear 8 Check Sbearing Soil seal Damage wear Replace the defective part s ...

Page 424: ...ab a on the brush holder with the slot b in the starter motor yoke 2 Install Sarmature coil 1 Swashers 2 Sstarter motor front cover 3 Sstarter motor rear cover 4 Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers 3 Install SO rings New 1 SStarter motor bolts 2 ...

Page 425: ...8 25 CHARGING SYSTEM ELEC 2 Generator 3 Rectifier regulator 4 Main fuse 5 Battery EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 426: ...charge or re place the battery CHARGING SYSTEM ELEC NOTE YES NO 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK Replace the fuse 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20_C SIs the battery OK EAS00774 TROUBLESHOOTING The batter...

Page 427: ...s wiring EAS00779 Replace the rectifi er regulator YES NO 4 Stator coil resistance SRemove the generator cover SConnect the pocket tester Ω 1 to the sta tor coils as shown Replace the stator coil assembly EAS00776 Positive tester probe white Negative tester probe white Positive tester probe white Negative tester probe white 1 1 2 3 SMeasure the stator coil resistances Stator coil resistance 0 18 X...

Page 428: ...y 9 Main switch 38 High beam indicator light 41 Meter light 45 Light switch 50 Pass switch 51 Dimmer switch 58 Headlight fuse 60 Parking light fuse 62 Auxiliary light 64 Tail brake light switch 65 Headlight EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 429: ...he main switch EAS00749 LIGHTING SYSTEM ELEC NOTE YES NO 1 Main parking lighting and headlight fuses SCheck the main parking lighting and head light fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main parking lighting and headlight fuses OK Replace the fuse s EAS00781 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight auxilia r...

Page 430: ...ss switch for continuity Refer to CHECKING THE SWITCHES SIs the pass switch OK The pass switch is faulty Replace the left handlebar switch EAS00787 YES NO 7 Wiring SCheck the entire lighting system s wiring Refer to CIRCUIT DIAGRAM SIs the lighting system s wiring properly con nected and without defects Properly connect or repair the lighting system s wiring Check the condition of each of the ligh...

Page 431: ...cuit from the main switch to the headlight cou pler is faulty and must be repaired When the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Headlight Positive tester probe yellow or blue black Negative tester probe black High beam indicator light Positive tester probe yellow Negative tester probe black white 1 2 3 4 5 Meter assembly coupler wire harness...

Page 432: ... meter assembly coupler wire harness side SIs the voltage within specification 1 This circuit is OK EAS00790 3 The tail brake light fails to come on YES NO 1 Tail brake light bulb and socket SCheck the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the tail brake light bulb and socket OK Replace the tail brake light bulb socket or both YES NO 2 Vo...

Page 433: ...2 Voltage The wiring circuit from the main switch to the auxiliary light coupler is faulty and must be repaired SConnect the pocket tester DC 20 V to the auxiliary light coupler wire harness side as shown Positive tester probe blue red Negative tester probe black 1 2 SSet the main switch to ON SSet the light switch to or SMeasure the voltage DC 12 V of blue red on the auxiliary light coupler wire ...

Page 434: ...8 34 SIGNALING SYSTEM ELEC EAS00780 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 435: ...eft turn signal indicator light 40 Right turn signal indicator light 42 Oil level switch 44 Front brake light switch 49 Horn switch 52 Hazard switch 53 Turn signal switch 55 Turn signal relay 56 Horn 59 Hazard light fuse 61 Signaling system fuse 63 Rear brake light switch 64 Tail brake light switch 66 Rear turn signal light left 67 Rear turn signal light right 68 Front turn signal light left 69 Fr...

Page 436: ... Refer to CHECKING THE SWITCHES SIs the main switch OK Replace the main switch EAS00749 NOTE YES NO 1 Main signaling system hazard lighting windshield motor and backup fuses SCheck the main signaling system hazard lighting windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main signaling system hazard light ing windshield motor and backup fuses OK R...

Page 437: ...NO 2 Voltage SDisconnect the black connector at the horn terminal SConnect a jumper lead to the horn termi nal and ground the jumper lead SSet the main switch to ON SPush the horn switch SDoes the horn sound YES The horn is OK NO 3 Horn EAS00796 CHECKING THE SIGNAL SYSTEM 1 The horn fails to sound 1 Horn switch Positive tester probe black white Negative tester probe ground 1 SSet the main switch t...

Page 438: ...ire harness side as shown Positive tester probe yellow Negative tester probe black 1 2 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired NO This circuit is OK SSet the main switch to ON SPull in the brake lever or push down on the brake pedal SMeasure the voltage DC 12 V of yellow on the tail brake light coupler wire harness side SIs the vol...

Page 439: ...brown green Negative tester probe ground 1 SSet the main switch to ON SMeasure the voltage DC 12 V on brown green at the turn signal relay coupler wire harness side SIs the voltage within specification 1 Positive tester probe brown white Negative tester probe ground 1 SSet the main switch to ON SSet the turn signal switch to or SMeasure the voltage DC 12 V on brown white at the turn signal relay c...

Page 440: ... 1 2 SSet the main switch to ON SSet the turn signal switch to or SMeasure the voltage DC 12 V of the choco late or dark green at the turn signal light coupler wire harness side SIs the voltage within specification 1 2 This circuit is OK A B A B 1 Neutral indicator light bulb and socket SCheck the neutral indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS S...

Page 441: ... cut off relay from the wire harness SConnect the pocket tester Ω 1 to the starting circuit cut off relay terminals as shown SCheck the starting circuit cut off relay for continuity When you switch the positive and negative tester probes the readings in the above chart will be reversed SAre the tester readings correct Tester positive probe sky blue Tester negative probe light green Tester positive...

Page 442: ...ine oil and remove the engine oil level switch from the oil tank SCheck the engine oil level switch for continu ity Refer to CHECKING THE SWITCHES SIs the engine oil level switch OK NO YES Replace the engine oil level switch 3 Voltage SConnect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown YES The wiring circuit from the main switch to the meter assem bly couple...

Page 443: ...sembly wire harness side as shown YES Positive tester probe green Negative tester probe black white SSet the main switch to ON SMeasure the voltage DC 12 V of green and black white at the meter assembly coupler SIs the voltage within specification 1 2 1 2 EAS00803 6 The fuel level gauge fails to operate Fuel sender resistance Full position of the float 19 X 21 Ω at 20_C Empty position of the float...

Page 444: ...red NO 1 Voltage SConnect the pocket tester DC V 20 to the meter assembly wire harness side as shown YES EAS00805 7 The clock fails to operate Positive tester probe brown Negative tester probe black white 1 SSet the main switch to ON SMeasure the voltage DC 12 V SIs the voltage within specification Replace the meter assembly 2 ...

Page 445: ... SYSTEM ELEC 4 Main fuse 5 Battery 9 Main switch 22 Coolant temperature sensor 24 ECU 57 Ignition fuse 70 Radiator fan motor fuse 71 Radiator fan relay 72 Radiator fan motor EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 446: ...n ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main ignition and radiator fan motor fuses OK Replace the fuse s EAS00808 TROUBLESHOOTING The radiator fan motor fails to turn The water temperature gauge needle fails to move when the engine is warm Check 1 main turn signal and radiator fan motor fuses 2 battery 3 main switch 4 radiator fan m...

Page 447: ...ermo switch to strong shocks If the thermo switch is dropped replace it Coolant temperature sensor 20 Nm 2 0 mSkg Three bond sealock 10 YES NO 4 Radiator fan motor SDisconnect the radiator fan motor coupler from the wire harness SConnect the battery DC 12 V as shown Positive battery lead blue Negative battery lead black The radiator fan mo tor is faulty and must be replaced SDoes the radiator fan ...

Page 448: ...ed above Replace the coolant temperature sensor NO YES 7 Wiring SCheck the entire cooling system s wiring Refer to CIRCUIT DIAGRAM SIs the cooling system s wiring properly con nected and without defects Properly connect or repair the cooling system s wiring NO YES This circuit is OK EAS00813 ...

Page 449: ...20 Atmospheric pressure sensor 21 Intake air temperature sensor 22 Coolant temperature sensor 23 Lean angle cut off switch 24 ECU 25 O2 sensor 26 Cylinder 1 injector 27 Cylinder 2 injector 28 AI system solenoid 29 Intake solenoid 32 Fuel pump 33 Throttle position sensor 46 Engine stop switch 57 Ignition fuse FUEL INJECTION SYSTEM ELEC EAS00814 FUEL INJECTION SYSTEM CIRCUIT DIAGRAM ...

Page 450: ... the main fuel injection system and ignition fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main fuel injection system and igni tion fuses OK Replace the fuse s EAS00816 TROUBLESHOOTING If the fuel injection system fails to operate Check 1 main fuel injection system and ignition fuses 2 battery 3 main switch 4 engine stop switch 5 fuel injection system relay 6 fuel pump re...

Page 451: ...sitive probe red blue Tester negative probe black 1 2 SMeasure the fuel pump resistance Fuel pump resistance 0 2 X 3 0 Ω at 20_C SIs the fuel pump OK EAS00748 7 Crankshaft position sensor resistance SDisconnect the crankshaft position sensor coupler from the wire harness SConnect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown YES NO Tester positive probe red Tester nega...

Page 452: ...blue 1 2 SMeasure the speed sensor output voltage Speed sensor output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less SIs the speed sensor OK SSet the main switch to ON SMeasure the cylinder identification sensor output voltage YES NO Replace the crank shaft position sensor Crankshaft position sensor resis tance 420 X 569 Ω at 20_C between gray and black SIs the cran...

Page 453: ...t temperature sensor for continuity at the temperatures indicated be low 10 Coolant temperature sensor 1 WARNING SHandle the coolant temperature sensor with special care SNever subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it Coolant temperature sensor 20 Nm 2 0 mSkg Three bond sealock 10 NOTE SDoes the coolant temperature sensor oper ...

Page 454: ...wn Replace the intake air pressure sensor Tester positive probe pink white Tester negative probe black blue 1 2 SSet the main switch to ON SMeasure the intake air pressure sensor out put voltage Intake air pressure sensor output voltage 3 75 X 4 25 V SIs the intake air pressure sensor OK Tester positive probe brown white Tester negative probe black blue 1 2 SMeasure the intake air temperature sens...

Page 455: ...eplace the atmo spheric pressure sensor SIs the atmospheric pressure sensor OK 15 Intake solenoid SRemove the intake solenoid coupler from the wire harness SConnect the pocket tester Ω 1 to the AI system solenoid terminal as shown Tester positive probe brown black Tester negative probe red white 1 2 YES NO Replace the intake solenoid SMeasure the intake solenoid resistance Intake solenoid resistan...

Page 456: ...spill gasoline wipe it up immediately with dry rags SIf gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Check SFuel pump operation a Insert the plug 1 to fuel return hose end b Fill the fuel tank c Put the end of the fuel hose into an open con tainer d Connect the battery DC 12 V to the fuel pump ...

Page 457: ...easure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor Maximum throttle position sensor resistance 4 0 X 6 0 kΩ at 20_C blue black blue d Connect the pocket tester Ω 1k to the throttle position sensor Tester positive probe yellow terminal 3 Tester negative probe black blue terminal 2 e While slowly opening the throttle check that the throt...

Page 458: ... probe black blue terminal 2 c Measure the throttle position sensor output voltage Throttle position sensor output voltage 4 95 X 5 05 V Out of specification SCheck the throttle sensor coupler connection SCheck the entire fuel injection system s wiring 3 Adjust Sthrottle position sensor angle a Lift the throttle body assembly slightly out of the intake manifolds b Loosen the throttle position sens...

Page 459: ... throttle position sensor angle so the measured output voltage is within the specified range Throttle position sensor output voltage 0 53 X 0 83 V e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 4 ...

Page 460: ......

Page 461: ...9 TRBL SHTG ...

Page 462: ...ORMANCE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH 9 4 CLUTCH SLIPS 9 4 CLUTCH DRAGS 9 4 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 ELECTRICAL SYSTEMS 9 4 OVER COOLING 9 5 COOLING SYSTEM 9 5 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9...

Page 463: ... NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT COME ON 9 6 TURN SIGNAL BLINKS SLOWLY 9 6 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 HORN DOES NOT SOUND 9 6 ...

Page 464: ...ESHOOTING The following guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING FAILURES ENGINE Cylinder s and cylinder head s SLoose spark plug SLoose cylinder head or cylinder SDamaged cylinder head gasket SDa...

Page 465: ... plug lead SCracked or broken ignition coil Ignition system SFaulty ignitor unit SFaulty pickup coil SBroken generator rotor woodruff key EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s SIncorrect valve clearance SDamaged valve train components Air filter SClogged air filter element FUEL SYSTEM Throttle body ies SDamaged or loose throttle body joint SImproperly synchro...

Page 466: ...ear dog EAS00849 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES ENGINE Air filter SClogged air filter element EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft SImproperly adjusted shift rod SBent shift shaft Shift drum and shift forks SForeign object in a shift drum groove SSeized shift fork SBent shift fork guide ba...

Page 467: ...U EAS00852 FAULTY CLUTCH CLUTCH SLIPS Clutch SImproperly assembled clutch SImproperly assembled clutch master cylinder SImproperly assembled clutch release cylinder SIncorrect clutch fluid level SDamaged clutch hose SLoose or fatigued clutch spring SLoose union bolt SWorn friction plate SWorn clutch plate SDamaged clutch release cylinder Engine oil SIncorrect oil level SIncorrect oil viscosity low...

Page 468: ...ease on the brake pad SIncorrect brake fluid level EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL SBent damaged or rusty inner tube SCracked or damaged outer tube SImproperly installed oil seal SDamaged oil seal lip SIncorrect oil level high SLoose damper rod assembly bolt SDamaged damper rod assembly bolt copper washer SCracked or damaged cap bolt O ring SLoose drain bolt SDamaged drain bolt gasket ...

Page 469: ...NG Handlebar SBent or improperly installed handlebar Steering head components SImproperly installed upper bracket SImproperly installed lower bracket improperly tightened ring nut SBent steering stem SDamaged ball bearing or bearing race Front fork leg s SUneven oil levels both front fork legs SUnevenly tensioned fork spring both front fork legs SBroken fork spring SBent or damaged inner tube SBen...

Page 470: ...njection system fuse 7 Starter relay 8 Starter motor 9 Main switch 10 Alarm 11 Diode 12 Buck up fuse 13 Starting circuit cut off relay 14 Sidestand switch 15 Neutral switch 16 Cylinder identification sensor 17 Fuel injection system relay 18 Throttle position sensor 19 Intake air pressure sensor 20 Atmospheric pressure sensor 21 Intake air temperature sensor 22 Coolant temperature sensor 23 Lean an...

Page 471: ... motor 9 Main switch 10 Diode 11 Buck up fuse 12 Starting circuit cut off relay 13 Sidestand switch 14 Neutral switch 15 Cylinder identification sensor 16 Fuel injection system relay 17 Throttle position sensor 18 Intake air pressure sensor 19 Atmospheric pressure sensor 20 Intake air temperature sensor 21 Coolant temperature sensor 22 Lean angle cut off switch 23 ECU 24 O2 sensor 25 Injector 1 26...

Page 472: ......

Page 473: ......

Page 474: ... P W R B R L G B B L B L B W R G W L R B R L G B L Y Y R R B B R R R B W B W Wire harness Headlight sub wire harness 2 Wire harness Headlight sub wire harness 1 L Y B L Y B B L R L R L B B Y L B R Y Dg Y R Y L Y Br W B R G Br Lg Dg B W Y L W Y Ch L G B L P W L B R W Br B B L Br W R L R B R L G B Br Y B B 187 187 Ch B Ch B 1 2 3 4 6 5 7 8 11 12 13 17 9 10 57 58 43 45 44 46 47 15 14 16 18 19 20 21 2...

Page 475: ...TDM900P 2002 WIRING DIAGRAM OCE ...

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