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IMPORTANT INFORMATION

1-8

EAS20230

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers 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.

CAUTION:

ECA13300

Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.

EAS20240

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

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Summary of Contents for 2005 MT-01

Page 1: ...2005 SERVICE MANUAL MT 01 T 5YU1 AE1 ...

Page 2: ...1 T 2005 SERVICE MANUAL 2004 by Yamaha Motor Co Ltd First edition December 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...dels 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 NOTE Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Aler...

Page 4: ... page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruc...

Page 5: ...6 LT New T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part with a new one ...

Page 6: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8 ...

Page 7: ...GEN INFO 1 ...

Page 8: ...OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 ...

Page 9: ......

Page 10: ...CLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the lead holder under the seat This information will be needed to order spare parts 1 1 ...

Page 11: ...com modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors The adoption of the FI system...

Page 12: ...iming are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is ...

Page 13: ...nd RESET buttons except for setting the brightness control For the U K only To switch the speedometer and odometer tripmeter fuel reserve tripmeter displays between kilometers and miles press the SELECT button for at least two seconds Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer...

Page 14: ...light will come on and then the multifunction display will indicate a two digit er ror code e g 12 13 14 If the multifunction display indicates an error code note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 7 25 CAUTION EC5YU1010 If the multifunction display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine dama...

Page 15: ...el by pushing the RESET button 5 Push the SELECT button to select the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the RESET button 6 Push the SELECT button to select the ta chometer needle Item number 3 is displayed Adjust the tachometer needle brightness lev el by pushing the RESET button 7 Push the SELECT button and the multi function display will return to the odom...

Page 16: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 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 but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 17: ...rease Oil bearings liberally when installing if appropriate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned o...

Page 18: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at ...

Page 19: ... any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 9 5 72 7 91 7 92 7 93 7 96 7 97 7 98 7 99 7 100 7 101 7 102 7 103 7 104 7 106 7 107 7 108 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 4 3 5 5 56 Locknu...

Page 20: ...0 01403 Spanner wrench YU 33975 3 26 4 59 Vacuum pressure pump gauge set 90890 06756 4 5 6 9 Fork spring compressor 90890 01441 YM 01441 4 50 4 55 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 50 4 55 Damper rod holder 90890 01504 4 51 4 52 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 53 Tool name Tool No Illustration Reference pages ...

Page 21: ... nut wrench 90890 01268 Spanner wrench YU 01268 4 59 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 13 Valve spring compressor 90890 04019 YM 04019 5 35 5 40 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 36 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 36 Tool name Tool No Illustration Reference pages YM A8703 YM A8...

Page 22: ...01304 5 42 Universal clutch holder 90890 04086 YM 91042 5 55 5 58 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 55 5 57 5 68 5 69 5 77 5 79 Yamaha bond No 1215 90890 85505 5 57 5 69 5 78 Rotor puller 90890 01080 Stator rotor puller YM 01080 A 5 68 Pressure gauge 90890 03153 6 9 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 23: ...S 1 14 Fuel pressure adapter 90890 03176 YM 03176 6 9 Digital circuit tester 90890 03174 6 10 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 100 Tool name Tool No Illustration Reference pages ...

Page 24: ...SPEC 2 ...

Page 25: ... 14 TIGHTENING TORQUES 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTENING TORQUES 2 23 LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ENGINE 2 28 CHASSIS 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 CABLE ROUTING 2 41 ...

Page 26: ......

Page 27: ...Dimensions Overall length 2185 mm 86 0 in Overall width 790 mm 31 1 in Overall height 1160 mm 45 7 in Seat height 825 mm 32 5 in Wheelbase 1525 mm 60 0 in Ground clearance 143 mm 5 63 in Minimum turning radius 3200 mm 126 0 in Weight With oil and fuel 259 0 kg 571 lb Maximum load 202 kg 445 lb ...

Page 28: ...e SAE20W40 Recommended engine oil grade API standard SE or higher grade ACEA standard G4 or G5 Engine oil quantity Total amount 5 00 L 5 29 US qt 4 40 Imp qt Engine 2 2 L 2 33 US qt 1 94 Imp qt Oil tank 2 8 L 2 96 US qt 2 46 Imp qt Without oil filter cartridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Oil filter Oil filter type Ca...

Page 29: ...1 38 243 38 343 mm 1 5056 1 5096 in cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 Intake B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Exhaust A 38 236 38 336 mm 1 5054 1 5093 in Limit 38 136 mm 1 5014 in Exhaust B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Rocker arm rocker arm shaft Rocker arm inside diameter 18 000 18 018 mm 0 70...

Page 30: ...m 0 0354 0 0433 in Limit 2 0 mm 0 08 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 2 0 mm 0 08 in Valve margin thickness D intake 0 70 1 30 mm 0 0276 0 0512 in Limit 0 4 mm 0 02 in Valve margin thickness D exhaust 0 70 1 30 mm 0 0276 0 0512 in Limit 0 4 mm 0 02 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 2341 in Valve stem diameter exhaust 5 9...

Page 31: ... 25 lb in 0 90 kgf mm Installed compression spring force intake 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Installed compression spring force exhaust 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Spring tilt intake 2 5 1 7 mm 2 5 0 067 in Spring tilt exhaust 2 5 1 7 mm 2 5 0 067 in Winding direction intake Counterclockwise Winding direction exhaust Counterclockwise Outer spring Free length intake 43 ...

Page 32: ...ter to valve lifter hole clearance 0 026 0 059 mm 0 0010 0 0023 in Valve push rod Valve push rod 1 length 288 5 mm 11 36 in Valve push rod 2 length 290 5 mm 11 44 in Valve push rod runout 0 3 mm 0 012 in Cylinder Bore 97 000 97 010 mm 3 8189 3 8193 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 025 0 050 mm 0 0010 0 0020 in Limit 0 15 ...

Page 33: ...nd ring Ring type Taper Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 30 0 45 mm 0 01 0 02 in Limit 0 80 mm 0 0315 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in Oil ring Dimensions B T 2 50 3 40 mm 0 10 0 13 in End gap installed 0 20 0 70 mm 0 01 0 03 in Connecting rod Oil clearance using plastigauge 0 050 0 074 mm 0 0020 0 0029 in Bearing color code...

Page 34: ... 0 1110 in Plate quantity 10 pcs Clutch plate thickness 1 90 2 10 mm 0 07 0 08 in Plate quantity 9 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring free length 6 88 mm 0 27 in Minimum length 6 38 mm 0 25 in Spring quantity 1 pcs Clutch housing thrust clearance 0 100 0 110 mm 0 0039 0 0043 in Clutch housing radial clearance 0 020 0 066 mm 0 0008 0 0026 in Transmission Transmission type Constant me...

Page 35: ...ity INP 101 2 Manufacturer NIPPON INJECTOR Throttle body Type quantity AC40 2 Manufacturer MIKUNI ID mark 5YU1 00 Throttle valve size 100 Throttle position sensor Resistance 4 0 6 0 kΩ blue black Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω gray black Intake pressure sensor output voltage 2 4 V Engine temperature sensor resistance 0 90 1 ...

Page 36: ...mit 0 5 mm 0 02 in Front tire Type Tubeless Size 120 70 ZR17 M C 58W Manufacturer model METZELER MEZ4J FRONT Europe MICHELIN PILOT ROAD S AUS Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 190 50 ZR17 M C 73W Manufacturer model METZELER MEZ4 Europe MICHELIN PILOT ROAD AUS Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front ...

Page 37: ... 00 mm 1 06 in Caliper cylinder inside diameter 30 23 mm 1 19 in Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal free play 7 9 19 0 mm 0 31 0 75 in Rear disc brake Disc outside diameter thickness 267 0 6 0 mm 10 51 0 24 in Brake disc thickness limit 5 5 mm 0 22 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 5...

Page 38: ...n Inner tube outer diameter 43 0 mm 1 69 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Recommended oil Suspension oil 01 Quantity 583 0 cm 19 71 US oz 20 56 Imp oz Level 65 0 mm 2 56 in Spring preload adjusting positions Minimum 0 Standard 2 Maximum 5 Rebound damping adjusting positions With the adjusting screw fully turned in Minimum 17 click s out Standard 15 click s ou...

Page 39: ...load adjusting positions Installed spring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 145 0 mm 5 71 in Rebound damping adjusting positions With the adjusting knob fully turned in Minimum 20 click s out Standard 12 click s out Maximum 3 click s out Compression damping adjusting positions With the adjusting screw fully turned in Minimum 12 click s out Standard 10 click s out Ma...

Page 40: ...tance 2 16 2 64 Ω Secondary coil resistance 8 64 12 96 kΩ Spark plug cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F5YU MORIC Standard output 14 0 V 430 W 5000 r min Stator coil resistance 0 1280 0 1920 Ω Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH010AA SHINDENGEN No load regulated voltage 14 3 15 1 V Rectifier capac...

Page 41: ... Starter motor Model manufacturer 5YU MORIC Power output 0 90 kW Armature coil resistance 0 0081 0 0099 Ω Brush overall length 9 8 mm 0 39 in Limit 5 00 mm 0 20 in Brush spring force 7 36 11 04 N 26 49 39 74 oz 750 1126 gf Commutator diameter 28 5 mm 1 12 in Limit 27 5 mm 1 08 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768093 A JIDECO Amperage 180 0 A Coil resistance ...

Page 42: ...acturer G8R 30Y U3 OMRON Coil resistance 162 198 Ω Thermo unit Model manufacturer 5PX DENSO Resistance at 100 C 898 38 1098 02 Ω Fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Parking lighting fuse 10 0 A ECU fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 10 0 A Muffler cover fan fuse 15 0 A Auto decompression fuse 15 0 A Reserve fuse 25 0...

Page 43: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 44: ...b Rear exhaust pipe bolt M8 1 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe and catalyst pipe bolt M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe nut M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe and muffler bolt M8 2 20 Nm 2 0 m kg 14 ft lb Front exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint cover bolt M6 3 7 Nm 0 7 m kg ...

Page 45: ... M12 8 45 Nm 4 5 m kg 32 ft lb Cylinder head nut M10 4 39 Nm 3 9 m kg 28 ft lb Cylinder head stud bolt exhaust pipe M8 4 15 Nm 1 5 m kg 11 ft lb Clutch Crankshaft end cover plug M32 1 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessing screw M16 1 8 Nm 0 8 m kg 5 8 ft lb Clutch cover bolt M6 17 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor lead holder screw M6 7 10 Nm 1 0 m kg 7 2 ft lb Crankshaf...

Page 46: ...l delivery pipe 2 oil pump driven gear stopper bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil pump driven gear stopper bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Generator shaft bolt M8 1 28 Nm 2 8 m kg 20 ft lb Crankcase bolt M8 3 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 18 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt crankcase M14 1 43 Nm 4 3 m kg 31 ft lb Engine oil filler plug M20 1 10 Nm 1 0 m kg 7 2 ft l...

Page 47: ...e bolt drive sprocket side M8 3 24 Nm 2 4 m kg 17 ft lb Drive sprocket nut M22 1 95 Nm 9 5 m kg 68 ft lb Stake Fuel injection system surrounding parts Throttle body joint clamp screw M4 2 4 Nm 0 4 m kg 2 9 ft lb Throttle position sensor screw M5 2 5 Nm 0 5 m kg 3 6 ft lb Intake manifold assembly bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Injector joint screw M6 4 5 Nm 0 5 m kg 3 6 ft lb Fuel pipe bolt M12...

Page 48: ...TIGHTENING TORQUES 2 22 Oil tank tightening sequence Cylinder head tightening sequence 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 A Front cylinder B Rear cylinder ...

Page 49: ...g 38 ft lb Down tube nut front side M12 2 74 Nm 7 4 m kg 53 ft lb Down tube nut rear side M10 2 55 Nm 5 5 m kg 40 ft lb Engine mounting nut front lower side M12 1 94 Nm 9 4 m kg 68 ft lb Engine mounting nut rear lower side M12 1 74 Nm 7 4 m kg 53 ft lb Down tube spacer bolt M18 2 8 Nm 0 8 m kg 5 8 ft lb Engine mounting spacer bolt rear upper side M18 1 8 Nm 0 8 m kg 5 8 ft lb Engine mounting space...

Page 50: ...olt M6 2 7 Nm 0 7 m kg 5 1 ft lb Air duct bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Air duct bracket bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Positive battery lead bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Starter motor lead bolt starter relay side M6 1 7 Nm 0 7 m kg 5 1 ft lb Battery box bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Lead holder and sub frame bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Fuel pump bolt M5 6 4 Nm 0 4 m kg 2 9...

Page 51: ... 25 ft lb Bleed screw front brake caliper M8 2 6 Nm 0 6 m kg 4 3 ft lb Bleed screw front brake master cylinder M8 1 6 Nm 0 6 m kg 4 3 ft lb Front brake hose holder bolt M6 2 6 Nm 0 6 m kg 4 3 ft lb Rear brake Rear brake master cylinder bolt M8 2 23 Nm 2 3 m kg 27 ft lb Locknut rear brake master cylinder M8 1 16 Nm 1 6 m kg 11 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brak...

Page 52: ...light assembly bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Meter assembly bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight assembly bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front fork guard bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M6 4 6 Nm 0 6 m kg 4 3 ft lb Swingarm and rear shock absorber Swingarm pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Footrest bracket pinch bolt M8 2 25 Nm 2 5 m ...

Page 53: ... the lower ring nut completely 2 Retighten the lower ring nut to 23 Nm 2 3 m kg 17 ft lb with a torque wrench Drive chain guard bolt swingarm side M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive chain guide bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Locknut drive chain adjusting bolt M8 2 16 Nm 1 6 m kg 11 ft lb Item Thread size Q ty Tightening torque Remarks ...

Page 54: ... exhaust Valve stem ends intake and exhaust Valve lifters Rocker arms Rocker arm shafts Oil pump rotors inner and outer and oil pump housing Oil pump driven gear shaft Crankcase stud bolt ends Crankcase bush generator shaft journal Starter clutch idle gear inner surface Starter clutch idle gear shafts Starter clutch roller and starter clutch gears outer surface Crankshaft journal Primary driven ge...

Page 55: ...d shift fork guide bars Shift drum Shift shaft and shift shaft oil seal lip Crankcase mating surface Yamaha bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Lubrication point Lubricant E E LS ...

Page 56: ...ase Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Swingarm pivot shaft Bearing spacer and oil seal lips swingarm pivot shaft Bearing spacer and oil seal lips swingarm ...

Page 57: ...IAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 9 10 11 7 6 5 1 2 12 14 13 15 16 17 18 19 20 26 23 36 21 31 38 40 39 37 27 30 30 35 35 29 29 34 34 33 33 28 28 32 32 25 24 22 8 3 4 A ...

Page 58: ...ears 17 Clutch 18 Bypass valve 19 Oil filter cartridge 20 Generator shaft journal left 21 Generator shaft journal right 22 Starter clutch 23 Crankshaft journal camshaft cover side 24 Camshaft journal camshaft cover side 25 Camshaft lobe faces 26 Crankshaft journal right 27 Front cylinder 28 Crank pin 29 Connecting rod 30 Piston 31 Front camshaft 32 Valve lifter 33 Push rod 34 Rocker arm 35 Valve s...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 3 5 3 1 B B D D E E A C E E 2 1 B B D D 4 2 A C ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil delivery pipe 2 Push rod 3 Oil filter cartridge 4 Rocker arm shaft 5 Oil delivery pipe 2 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 4 3 2 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Rocker arm shaft 2 Crankshaft 3 Valve lifter 4 Push rod ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 3 2 1 1 A A B B B B A A ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pump 2 Oil strainer crankcase 3 Oil pipe 1 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 3 4 2 1 A ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil pump 4 Oil strainer crankcase A To oil filter cartridge ...

Page 67: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING A 10 11 12 13 1 2 3 4 5 6 6 6 8 9 14 15 16 17 7 H D E G I J B C F ...

Page 68: ... on the meter assembly bracket making sure to fit the grommet on the hose in the guide C Make sure that the brake hose three way joint contacts the tab on the front brake hose joint bracket D Fasten the wire harness stator coil assembly lead rectifier regulator lead and horn lead with the holder Face the fastener of the holder forward E Fasten the horn leads with the holder Face the open ends of t...

Page 69: ... D C B B C 17 A B C D E F G H I J K L M M N O P Q R S S T U V W X Y Z AC AB AA AE AF AG AG AH AI AD AK AL AM AN AJ D D C C B B A F E F A E 1 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 14 15 15 15 15 15 15 16 19 20 20 21 16 17 18 ...

Page 70: ...ft spark plug lead EXUP servo motor lead and negative battery lead Be sure not to cover the fuel hose Q Route the cylinder 1 left spark plug lead under the frame boss and to the outside of the wire harness and clutch hose R Route the clutch hose to the outside of the wire harness S Fasten the clutch hose and EXUP servo motor lead with the plastic locking ties Face the buckle of the plastic locking...

Page 71: ...TING 2 45 A B C 1 29 Z A B B C D E F G I H J K L M N Q O P S T U Y AF AB AA AB AC AE AD D D E C A B E D D 1 2 3 3 4 5 6 7 8 9 10 11 12 13 13 14 14 15 16 17 18 19 19 20 21 22 22 23 24 25 26 15 28 27 31 30 W V X R ...

Page 72: ...that are not covered by the protective sleeves M Route the cylinder 2 intake air pressure sensor hose to the outside of the wire harness N Route the cylinder 2 intake air pressure sensor lead to the outside of the wire harness headlight lead right handlebar switch lead main switch lead and cylinder 2 left spark plug lead O Fasten the wire harness headlight lead right handlebar switch lead main swi...

Page 73: ...CABLE ROUTING 2 47 A A K L U A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 S T U V W X AF AA AB AC AD AE Y Z ...

Page 74: ...e hole in the frame I When installing the rear brake fluid reservoir be sure not to pinch the tail brake light lead and muffler cooling fan motor lead between the rear brake fluid reservoir and the rear brake fluid reservoir bracket Route the leads under the damper that is attached to the frame J Fasten the rear turn signal light leads tail brake light lead muffler cooling fan motor lead and licen...

Page 75: ...CABLE ROUTING 2 49 A A K L U A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 S T U V W X AF AA AB AC AD AE Y Z ...

Page 76: ...s to the left of the battery box Be sure not to pinch the seat lock cable when installing the battery box AD Fasten the sub wire harness 1 at the white tape with the plastic locking tie Face the end of the plastic locking tie rearward and then cut off the excess end of the tie AE To cylinder 1 left spark plug AF Fasten the starter motor lead at the white tape with the holder on the cylinder 1 left...

Page 77: ...CABLE ROUTING 2 51 A A B D D E F G C 1 2 3 3 4 4 5 6 7 8 9 ...

Page 78: ...ose contacts the paint mark on the pipe C Connect the end of the fuel hose that has a black connector to the fuel pipe D Face the end of the hose clamp inward angled slightly downward E Install the end of the fuel return hose fuel return pipe to fuel pump with a yellow paint mark onto the fuel return pipe until the hose contacts the yellow paint mark on the pipe F Install the fuel return hose fuel...

Page 79: ...CABLE ROUTING 2 53 A A A A A B C D D E F A A 1 1 2 2 5 3 6 8 10 10 11 A G H I K J 4 7 9 9 9 ...

Page 80: ...tall the rollover valve hoses with their paint marks facing outward E Fasten the fuel tank breather hose at the white paint mark fuel tank overflow hose at the yellow paint mark and fuel return pipe with the holder Fasten the hoses in the order listed with the fuel tank breather hose fastened towards the front of the vehicle F Install the rollover valve hoses with their paint marks facing downward...

Page 81: ...CABLE ROUTING 2 55 B A B A C C A A B C D E J 1 2 3 4 5 8 6 7 8 9 10 11 12 13 G H I K L M N F 14 15 16 17 10 E 3 ...

Page 82: ...all the end of the cylinder 1 ISC idle speed control unit outlet hose with a white paint mark onto the throttle body D Face the ends of the hose clamp to the left angled 45 towards the rear of the vehicle E Face the ends of the hose clamp forward F Install the end of the cylinder 1 intake air pressure sensor hose with a white paint mark onto the throttle body G Face the ends of the hose clamp inwa...

Page 83: ...CHK ADJ 3 ...

Page 84: ...K BREATHER HOSE 3 17 CHECKING THE EXHAUST SYSTEM 3 17 ADJUSTING THE EXUP CABLES 3 18 CHASSIS 3 20 ADJUSTING THE FRONT DISC BRAKE 3 20 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSES 3 22 CHECKING THE REAR BRAKE HOSE 3 22 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 22 BLEEDING THE ...

Page 85: ...ELECTRICAL SYSTEM 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULBS 3 33 ADJUSTING THE HEADLIGHT BEAM 3 34 ...

Page 86: ...tion Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 Clutch Check operation fluid level and vehicle for fluid leakage 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 8 ...

Page 87: ...es every four years and if cracked or damaged 19 Shock absorber as sembly Check operation and shock absorber for oil leakage 20 Rear suspension re lay arm and connect ing arm pivoting points Check operation 21 Fuel injection system Adjust synchronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Front and rear brake switches Check o...

Page 88: ...in specification If clearance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fue...

Page 89: ...hickness gauge Piston 2 TDC front cylinder a Turn the crankshaft counterclockwise from the piston 1 TDC by 408 degrees b When piston 2 is at TDC on the compres sion stroke align the TDC mark e on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown d Measure the valve clearanc...

Page 90: ...btained 9 Install All removed parts NOTE For installation reverse the removal procedure Front cylinder head cover Tappet covers Refer to CAMSHAFTS on page 5 16 EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level...

Page 91: ...ified en gine idling speed b With throttle body 1 as standard adjust throttle body 2 using the air screw 1 for throttle body 2 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION EC5YU1027 Do not use the throttle valve a...

Page 92: ...nt LOCTITE to the threads of the adjusting nut 3 c Loosen the locknut 4 on the accelerator ca ble d Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained e Tighten the locknuts 2 4 NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loose...

Page 93: ...e 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark p...

Page 94: ...ASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel ...

Page 95: ... valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Refer to the following table 9 Install Spark plug 10 Connect Spark plug cap 11 Connect Decompression solenoid couplers 12 Install Fuel tank Refer to FUEL TANK on page 6 1 Seat Re...

Page 96: ...ubricates the clutch 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 Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again NOTE Before...

Page 97: ...filter wrench e Install the rectifier regulator 9 Check Engine oil drain bolt gaskets Damage Replace 10 Install Engine oil drain bolt crankcase along with the gasket Engine oil drain bolt oil tank along with the gasket 11 Fill Oil tank with the specified amount of the recom mended engine oil Oil filter wrench 90890 01426 YU 38411 1 1 1 1 1 2 2 T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb T R R...

Page 98: ...ghtly loosen the oil gallery bolts 1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolts If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 81 d Start the engine after solving the problem s an...

Page 99: ...tely NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal EAS20910 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed the hydraulic clutch system whenever the system was disassembled a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty NOTE Be careful not to spill any clutch flui...

Page 100: ... of the fuel tank and then tilt it back and away from the air filter case Do not disconnect the fuel hoses 3 Remove Air filter case cover 1 4 Remove Air filter element 1 5 Check Air filter element Damage Replace NOTE Replace the air filter element every 40000 km of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 6 Install Air filter case cover...

Page 101: ...se Cracks damage Replace Loose connection Connect properly CAUTION ECA14940 Make sure the fuel tank breather hose is rout ed correctly 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Seat Refer to GENERAL CHASSIS on page 4 1 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSES 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer t...

Page 102: ...pe and rear exhaust pipe bolt 7 Rear exhaust pipe and rear exhaust pipe joint bolt 8 Rear exhaust pipe bolt 9 Rear exhaust pipe and catalyst pipe bolt 10 Catalyst pipe nut 11 Catalyst pipe and muffler bolts 12 Muffler bolts 13 NOTE When installing the EXUP cables make sure they are parallel and not twisted Upper cable Black metal section 14 Lower cable White metal section 15 1 T R Front exhaust pi...

Page 103: ...d the stopper c fully closed posi tion 3 Check EXUP cable free play at the EXUP valve pul ley a 4 Adjust EXUP cable free play a Slide back the rubber cover b Loosen both locknuts 1 c Insert a 3 5 mm 0 14 in pin 2 through the projections a in the EXUP valve pulley and into the hole b in the EXUP valve cover d Turn both adjusting nuts 3 in or out until the specification 15 14 1 b c a EXUP cable free...

Page 104: ...ain switch to ON check that the EXUP valve pulley contacts the stoppers ful ly open and fully closed positions and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve cover 5 Install EXUP valve pulley cover T R EXUP valve pulley cover bolt 10 Nm 1 0 m kg 7 2 ft lb 3 3 d d c d d c c ...

Page 105: ... THE REAR DISC BRAKE NOTE The brake pedal position is determined by the in stalled rear brake master cylinder length a 1 Measure Installed rear brake master cylinder length a Incorrect Adjust 2 Adjust Installed rear brake master cylinder length a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified installed rear brake master cylinder length is obtained WARNING ...

Page 106: ...ARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill 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 performance When refilling be careful that water does not enter the brake fluid reservoir...

Page 107: ...ed hoses Refer to FRONT BRAKE on page 4 18 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check Brake hoses 1 Cracks damage wear Replace 3 Check Brake hose guide 2 Loose Tighten the clamp bolt 4 Hold the vehicle upright and apply the brake several times 5 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 31 6 In...

Page 108: ...leeding procedure If 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 Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the...

Page 109: ... b until the specified installed shift rod length is ob tained c Tighten both locknuts to specification EAS21390 ADJUSTING THE DRIVE CHAIN SLACK CAUTION ECA13550 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 swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the ...

Page 110: ...re washing certain solvents and the use of a coarse brush can damage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS21510 CHECKING AND ADJUST...

Page 111: ...age 4 57 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on p...

Page 112: ...of stability Securely support the vehicle so that there is no danger of it falling over Spring preload CAUTION ECA13570 Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust Spring preload a Turn the adjusting bolt 1 in direction a or b Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positi...

Page 113: ...knut 2 b Turn the adjusting nut 3 in direction a or b Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 17 click s out Standard 15 click s out Maximum 1 click s out With the adjusting screw fully turned in Direction a turn in Compression damping is increased suspen...

Page 114: ...pring preload adjusting positions Installed spring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 145 0 mm 5 71 in c Installed spring length T R Locknut rear shock absorber spring preload adjusting nut 42 Nm 4 2 m kg 30 ft lb a b 1 3 2 c Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Re...

Page 115: ...en the tire tread reaches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Compression damping adjusting positions Minimum 12 click s out Standard 10 click s out Maximum 1 click s out With the adjusting screw fully turned in 1 a b Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear...

Page 116: ...cteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark p...

Page 117: ...ath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUS...

Page 118: ...h the head light bulb holder CAUTION ECA13690 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 it with a cloth moistened with alcohol or lacquer thinner d Connect Headlight coupler 3 Replace High beam headlight...

Page 119: ...Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover 4 Install Headlight assembly EAS21810 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b T R Headlight assembly bolt 7 Nm 0 7 m kg 5 1 ft lb Direction a Headlight beam is ...

Page 120: ...CHAS 4 ...

Page 121: ...NG THE FRONT BRAKE DISCS 4 24 REPLACING THE FRONT BRAKE PADS 4 25 REMOVING THE FRONT BRAKE CALIPERS 4 26 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 26 CHECKING THE FRONT BRAKE CALIPERS 4 27 ASSEMBLING THE FRONT BRAKE CALIPERS 4 27 INSTALLING THE FRONT BRAKE CALIPERS 4 27 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE FRONT BRAKE MASTER CYLI...

Page 122: ...LY 4 61 HANDLING THE REAR SHOCK ABSORBER 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE CONNECTING ARM AND RELAY ARM 4 62 INSTALLING THE CONNECTING ARM AND RELAY ARM 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM 4 65 REMOVING THE SWINGARM 4 67 CHECKING THE SWINGARM 4 67 INSTALL...

Page 123: ...1 2 Lead holder 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Main fuse 1 6 Battery band 1 7 Battery 1 8 Battery seat 1 9 Battery box 1 For installation reverse the removal procedure 4 5 7 8 4 3 1 6 9 2 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT ...

Page 124: ...ir duct 1 6 Bottom cover 1 7 Sub wire harness 3 coupler wire harness side 1 Disconnect 8 Headlight assembly coupler 1 Disconnect 9 Air temperature sensor coupler 1 Disconnect 10 Headlight assembly 1 For installation reverse the removal procedure 8 79 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft...

Page 125: ...connect 2 Tail brake light coupler 1 Disconnect 3 Rear right turn signal light coupler 1 Disconnect 4 Rear left turn signal light coupler 1 Disconnect 5 License plate light coupler 1 Disconnect 6 Tail brake light assembly 1 7 Muffler cooling fan motor assembly 1 For installation reverse the removal procedure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT 7 6 1 2 3 4 5 ...

Page 126: ... hose cylinder head to oil catch tank 1 5 Air filter case joint clamp screw 2 Loosen 6 Air filter case bracket 1 7 ISC idle speed control unit inlet hose 1 Disconnect 8 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 Disconnect 9 Air filter case 1 10 Air filter case valve 1 11 Oil catch tank breather hose 1 12 Oil catch tank 1 For installation reverse the removal procedure 1...

Page 127: ...se with the air filter case valve b Connect the vacuum pressure pump gauge set 1 to the air filter case valve 2 c Check that the air filter case valve operates when vacuum pressure is applied to the valve using the vacuum pressure pump gauge set Faulty Replace the air filter case valve Vacuum pressure pump gauge set 90890 06756 1 2 ...

Page 128: ...ke caliper 1 4 Right front brake caliper 1 5 Front wheel axle pinch bolt 1 Loosen 6 Front wheel axle 1 7 Front wheel 1 8 Collar 2 9 Dust cover 2 10 Front brake disc 2 For installation reverse the removal procedure T R 23 Nm 2 3 m kg 17 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib LT LT T R 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib LS LS 2 6 5 ...

Page 129: ...FRONT WHEEL 4 7 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly procedure 2 1 2 1 3 LS LS New New ...

Page 130: ...rewdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Front wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHEC...

Page 131: ...ust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE 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 stops put an...

Page 132: ...BRAKE DISCS Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the front brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 3 Lubricate Oil seal lips Collars 4 In...

Page 133: ... smoothly 6 Install Front brake calipers WARNING EWA13500 Make sure the brake hose is routed properly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs T R Front wheel axle 72 Nm 7 2 m kg 52 ft lb T R Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Front brake caliper bolt 35 Nm 3 5 m kg 25 ft lb ...

Page 134: ...n adjusting locknut 2 Loosen 3 Drive chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left drive chain puller 1 8 Right drive chain puller 1 9 Rear brake caliper bracket 1 10 Rear wheel 1 For installation reverse the removal procedure T R 150 Nm 15 0 m kg 110 ft lb T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib LT 8 7 6 1 9...

Page 135: ... 1 2 Rear wheel sprocket 1 3 Collar brake disc side 1 4 Collar wheel sprocket side 1 5 Dust cover 2 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Rear wheel drive hub damper 6 For installation reverse the removal procedure LS LS LT New 6 4 2 8 9 5 7 1 5 3 T R 18 Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb 6 6 LT ...

Page 136: ...4 14 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly procedure New 2 3 1 5 4 6 LS LS ...

Page 137: ... THE FRONT WHEEL on page 4 8 EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHECKING THE WHEELS on page 3 31 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 EAS22110 CHEC...

Page 138: ...ar wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 9 ET5YU1026 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 36 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a cris...

Page 139: ...de 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 6 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Drive chain slack 40 0 50 0 mm 1 57 1 97 in T R Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE 1 2 a ...

Page 140: ...procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Front brake pad 2 For installation reverse the removal procedure T R 6 Nm 0 6 m kg 4 3 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 3 3 4 2 6 5 ...

Page 141: ...rake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Right rearview mirror 1 8 Brake fluid reservoir bracket 1 9 Brake lever 1 10 Front brake light switch connector 2 Disconnect 11 Front brake light switch 1 12 Front brake hose union bolt 1 13 Copper washer 2 14 Front brake hose 1 15 Front brake master cylinder holder 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm ...

Page 142: ...linder 1 For installation reverse the removal procedure Removing the front brake master cylinder Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib 7 8 5 4 3 1 2 15 16 13 12 10 14 11 9 6 New ...

Page 143: ...4 21 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 144: ...e front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper 1 For installation reverse the removal procedure T R 35 Nm 3 5 m kg 25 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 4 2 3 New ...

Page 145: ...ove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 146: ...applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 6 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or r...

Page 147: ...imit a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads 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 ...

Page 148: ...brake system 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW5YU1006 Do not loosen the bolts 3 a Blo...

Page 149: ... cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to i...

Page 150: ... any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on...

Page 151: ...o CABLE ROUTING on page 2 41 NOTE Install the brake hose at a right angle to the front brake master cylinder as shown in the il lustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake fluid reservoir with the specified amount of the ...

Page 152: ...e system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 a ...

Page 153: ...pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 2 5 Brake pad insulator 2 6 Rear brake pad 2 7 Brake pad spring 2 For installation reverse the removal procedure T R 3 Nm 0 3 m kg 2 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib LS LT 3 2 1 7 7 6 5 4 5 4 ...

Page 154: ... 1 Brake fluid reservoir cap holder 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake master cylinder 1 For installation reverse the removal procedure T R 30 Nm 3 0 m kg 22 ft Ib New New T R 23 Nm 2 ...

Page 155: ...sassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 156: ...ain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal procedure T R 22 Nm 2 2 m kg 16 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib LS LT New 1 2 4 3 ...

Page 157: ... 1 3 Brake pad shim 2 4 Brake pad insulator 2 5 Rear brake pad 2 6 Brake pad spring 2 7 Brake caliper piston 2 8 Brake caliper piston seal 4 9 Bleed screw 1 For assembly reverse the disassembly procedure LS New New 9 2 1 6 4 3 5 4 3 7 6 8 8 T R 3 Nm 0 3 m kg 2 2 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 158: ...Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 5 Adjust Brake disc defl...

Page 159: ...el Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 ...

Page 160: ...id delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake ...

Page 161: ... 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 performance When 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 CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic pa...

Page 162: ... diaphragm Cracks damage Replace 4 Check Brake hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Rear brake ho...

Page 163: ...por lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake p...

Page 164: ...le grip 1 9 Clutch switch coupler 1 Disconnect 10 Clutch master cylinder holder 1 11 Clutch master cylinder assembly 1 12 Left handlebar switch 1 13 Handlebar grip 1 14 Upper handlebar holder 2 15 Handlebar 1 1 2 4 3 16 LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib 7 T R 20 Nm 2 0 m kg 14 ft Ib T R 14...

Page 165: ...emove Q ty Remarks 1 2 4 3 16 LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib 7 T R 20 Nm 2 0 m kg 14 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 15 5 5 8 7 6 1 11 12 10 9 14 14 13 16 LS LS 12 ...

Page 166: ...pport the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders 1 NOTE Temporarily tighten the nuts 2 3 Install Handlebar 1 Upper handlebar holders 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the ...

Page 167: ...aster cylinder assembly Clutch master cylinder holder 1 NOTE Align the mating surfaces of the clutch master cylinder holder with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt The clutch master cylinder holder has a punch mark b to distinguish it from the front brake master cylinder holder 8 Install Throttle grip Throttle cables Right handlebar switch 1 Grip end...

Page 168: ...e master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 7 T R Front brake master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft lb Throttle cable free play 3 0 5 0 mm 0 12 0 20 in 1 a ...

Page 169: ...WHEEL on page 4 6 1 Front fork guard 2 2 Front fender 1 3 Cap bolt 1 Loosen 4 Upper bracket pinch bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal procedure 6 5 1 4 1 2 3 T R 26 Nm 2 6 m kg 19 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 170: ... O ring 1 3 Washer 1 4 Damper adjusting rod 1 5 Spacer 1 6 Nut 1 7 Upper spring seat 1 8 Fork spring 1 9 Lower spring seat 1 10 Outer tube 1 11 Dust seal 1 12 Oil seal clip 1 13 Oil seal 1 14 Washer 1 15 Damper rod assembly 1 T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New ...

Page 171: ...everse the disassembly procedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New ...

Page 172: ...of the front fork legs 1 Position the collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 NOTE Use the side of the rod holder that is marked B c H...

Page 173: ... CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es wit...

Page 174: ... front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inne...

Page 175: ...p 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 3 2 1 1 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Rod puller 90890 01437 Universal ...

Page 176: ...ay spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Lower spring seat 1 Fork spring 2 U...

Page 177: ...usting bolt 11 into the cap bolt to specifi cation WARNING EWA13670 Always use a new cap bolt O ring CAUTION EC5YU1012 When tightening the spring preload adjust ing bolt 11 into the cap bolt be sure not to break the projections c on the collar 12 NOTE Hold the nut 4 using a proper tool that has a thickness of 3 mm 0 12 in or less n Remove the rod holder and fork spring com pressor 16 Install Cap b...

Page 178: ...ush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 27 T R Lower bracket pinch bolt 28 Nm 2 8 m kg 20 ft lb T R Cap bolt 20 Nm 2 0 m kg 14 ft lb T R Upper bracket...

Page 179: ...t 2 Meter assembly 1 3 Meter assembly bracket 1 4 Steering stem nut 1 5 Upper bracket 1 6 Headlight assembly bracket 1 7 Front brake hose joint 1 8 Front brake hose joint bracket 1 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 12 Lower ring nut 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 180: ... 21 Bearing outer race 2 For installation reverse the removal procedure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 110 Nm 11 0 m kg 80 ft lb LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 6 8 7 12 18 19 20 21 21 15 16 17 14 9 10 11 5 4 13 3 1...

Page 181: ... Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install new bearing races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set 4...

Page 182: ...t 2 NOTE Make sure that the tab a on the front brake hose joint bracket 1 contacts the side b of the front brake hose joint 2 4 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 47 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut T R Steering stem nut 110 Nm 11 0...

Page 183: ...olt 1 1 4 Rear shock absorber assembly 1 5 Collar Spacer Oil seal Bearing 2 1 2 1 6 Self locking nut Bolt Washer 1 1 2 7 Spacer 1 8 Oil seal Bearing 2 1 9 Relay arm 1 10 Spacer Oil seal Bearing 2 8 4 11 Connecting arm 1 12 Collar Spacer 2 1 For installation reverse the removal procedure T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib LS LS LS LS LS LS 5 12 12 4 ...

Page 184: ...ear shock absorb er at a point 40 mm 1 57 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear...

Page 185: ...l the relay arm with its R mark a facing to the right and its arrow mark b facing upward 4 Tighten Rear shock absorber assembly nut rear side Relay arm nut relay arm and connecting arm Recommended lubricant Lithium soap based grease Installed depth a 8 0 mm 0 31 in Installed depth b 4 0 mm 0 16 in Installed depth c 7 0 mm 0 28 in Installed depth d 0 5 1 0 mm 0 02 0 04 in 5 Relay arm 6 Connecting a...

Page 186: ...assembly nut front side Relay arm nut relay arm and swingarm 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 T R Relay arm nut relay arm and connecting arm 49 Nm 4 9 m kg 35 ft lb Recommended lubricant Lithium soap based grease T R Rear shock absorber assembly nut front side 49 Nm 4 9 m kg 35 ft lb T R Relay arm nut relay arm and swingarm 40 Nm 4 0 m kg 29 ft lb Dr...

Page 187: ... Rear brake hose guide 1 1 4 Rear brake hose holder 1 5 Drive chain adjusting bolt Locknut 2 2 6 Footrest bracket pinch bolt 2 Loosen 7 Swingarm pivot shaft nut 1 8 Swingarm pivot shaft 1 9 Collar 2 10 Spacer 1 11 Spacer 1 12 Drive chain 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT 13 ...

Page 188: ...installation reverse the removal procedure Removing the swingarm Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT 13 2 8 19 9 9 23 14 11 24 25 24 18 16 21 1710 20 7 22 5 5 4 3 6 6 1 12 19 15 New T R 25 Nm 2 5 m kg 18 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib LT...

Page 189: ...ment is not smooth or if there is binding check the spacers bear ings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 70 EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Space...

Page 190: ... bearing b 5 7 mm 0 22 in Installed depth of oil seal c 0 5 1 0 mm 0 02 0 04 in Installed depth of oil seal d 0 5 mm 0 02 in Installed depth of bearing e 4 0 mm 0 16 in Installed depth of oil seal f 1 0 mm 0 04 in 5 Swingarm 6 Swingarm pivot shaft 7 Relay arm 8 Bolt A Left side B Right side Drive chain slack 40 0 50 0 mm 1 57 1 97 in 1 1 2 2 5 6 d c a d b A B e f 3 4 7 5 8 A B ...

Page 191: ...p 1 3 Clutch pipe union bolt 1 4 Copper washer 2 5 Clutch pipe 1 6 Clutch release cylinder 1 7 Dowel pin 2 8 Drive chain guard drive sprocket side 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 1 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 95 Nm 9 5 m kg 68 ft Ib New New E LT LT 2 5 3 4 7 8 6 11 10 9 1 T R 26...

Page 192: ...nt at two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive 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 CAUTION EC5YU1022 This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plate...

Page 193: ...HE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 15 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Install the washer 2 with ...

Page 194: ...CHAIN DRIVE 4 72 3 Install Clutch release cylinder Refer to INSTALLING THE CLUTCH RE LEASE CYLINDER on page 5 62 a 1 2 3 New b ...

Page 195: ...ENG 5 ...

Page 196: ...NG THE DECOMPRESSION SYSTEM 5 26 CHECKING THE OIL DELIVERY PIPE 5 26 INSTALLING THE CAMSHAFTS 5 26 BLEEDING A VALVE LIFTER 5 27 INSTALLING THE VALVE LIFTERS 5 29 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 29 INSTALLING THE CYLINDER HEAD COVERS 5 30 CYLINDER HEADS 5 31 REMOVING THE CYLINDER HEADS 5 32 CHECKING THE CYLINDER HEADS 5 32 CHECKING THE OIL PIPE 5 32 INSTALLING THE CYLINDER HEADS 5 33 VAL...

Page 197: ...CH MASTER CYLINDER 5 60 INSTALLING THE CLUTCH MASTER CYLINDER 5 60 REMOVING THE CLUTCH RELEASE CYLINDER 5 61 CHECKING THE CLUTCH RELEASE CYLINDER 5 61 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 62 INSTALLING THE CLUTCH RELEASE CYLINDER 5 62 SHIFT SHAFT 5 64 CHECKING THE SHIFT SHAFT 5 65 CHECKING THE STOPPER LEVER 5 65 INSTALLING THE SHIFT SHAFT 5 65 GENERATOR AND STARTER CLUTCH 5 66 REMOVING THE GEN...

Page 198: ... REMOVING THE CONNECTING RODS 5 87 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 87 INSTALLING THE CONNECTING RODS 5 90 INSTALLING THE CRANKSHAFT ASSEMBLY 5 91 TRANSMISSION 5 92 CHECKING THE SHIFT FORKS 5 95 CHECKING THE SHIFT DRUM ASSEMBLY 5 95 CHECKING THE TRANSMISSION 5 95 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 96 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 96 ...

Page 199: ......

Page 200: ...k outlet pipe 1 5 Oil tank 1 6 Oil tank breather hose holder 1 7 Oil tank gasket 1 8 Oil strainer cover oil tank 1 9 Oil strainer oil tank 1 For installation reverse the removal procedure T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New LS LS LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3...

Page 201: ...d air ET5YU1028 CHECKING THE OIL STRAINER 1 Check Oil strainer oil tank Damage Replace Contaminants Clean with engine oil ET5YU1019 INSTALLING THE OIL TANK 1 Install Oil tank NOTE Tighten the oil tank bolts in the proper tightening sequence as shown T R Oil tank bolt 10 Nm 1 0 m kg 7 2 ft lb 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 ...

Page 202: ...et 2 10 Front exhaust pipe 1 11 Gasket 2 12 Rear exhaust pipe 1 13 Gasket 2 14 Catalyst pipe 1 For installation reverse the removal procedure LT LT T R 24 Nm 2 4 m kg 17 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib T R...

Page 203: ...er end cover plates 2 NOTE When installing a muffler end cover plate be sure to insert its hooks a two locations into the holes in the muffler cover and align its tabs b four locations with the grooves in the muf fler cover 2 Install Muffler end covers 1 NOTE When installing a muffler end cover align its pro jections a four locations with the grooves b in the muffler cover and then turn it in the ...

Page 204: ... pipe 2 Refer to GENERATOR AND STARTER CLUTCH on page 5 66 Drive sprocket Refer to CHAIN DRIVE on page 4 69 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 61 1 Rectifier regulator coupler 1 Disconnect 2 Stator coil assembly coupler 1 Disconnect 3 Rectifier regulator 1 4 Oil filter cartridge 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 ...

Page 205: ...ect 18 EXUP servo motor 1 19 O2 sensor coupler 1 20 Neutral switch coupler 1 Disconnect 21 Neutral switch 1 Removing the EXUP servo motor and rear exhaust pipe joint Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft ...

Page 206: ...Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib New New LS LS LS T R 24 Nm 2 4 m kg 17 ft Ib LT LS T R 20 Nm 2 0 m kg 14 ft Ib New New T R 17 Nm 1 7 m kg 12 ft Ib 1 2 3 4 6 5 8 7 21 14 13 16 23 22 15 12 10 11 18 19 20...

Page 207: ...oupler 2 Disconnect 5 Speed sensor coupler 1 Disconnect 6 Starter motor connector 1 7 Starter motor lead 1 8 Crankshaft position sensor coupler 1 Disconnect 9 Negative battery lead 1 Disconnect 10 Engine temperature sensor coupler 1 Disconnect 11 Spark plug cap 4 For installation reverse the removal procedure 3 6 11 11 9 5 8 4 1 2 10 7 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 208: ...de 1 8 Engine mounting nut front upper side 1 9 Engine mounting bolt front upper side 1 10 Engine bracket nut front upper side 4 11 Engine bracket bolt front upper side 4 12 Engine bracket front upper side 2 13 Down tube nut rear side 2 14 Down tube bolt rear side 2 T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft ...

Page 209: ...al procedure Removing the down tube Order Job Parts to remove Q ty Remarks T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib E LT LT E 5 17 14 4 3...

Page 210: ...gine bracket bolt rear upper side 2 6 Engine mounting nut rear lower side 1 7 Engine mounting spacer bolt rear lower side 1 Loosen 8 Engine mounting bolt rear lower side 1 9 Engine 1 10 Right side panel bracket 1 11 Cylinder 1 right ignition coil 1 12 Cylinder 1 left ignition coil 1 13 Ignition coil bracket 1 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 5...

Page 211: ...he removal procedure Removing the engine Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib E E T R 74 Nm 7 4 m kg 53 ft lb 2 1 3 10 14 11 13 12 6 7 4 5 8 9 T R 74 Nm 7 4 m kg 53 ft lb ...

Page 212: ... tube bolts rear side 11 Down tube nut rear side 12 temporarily tighten Engine mounting bolt front lower side 13 NOTE Do not fully tighten the bolts and nuts 5 Tighten Down tube spacer bolt 2 Engine mounting spacer bolt rear lower side 3 Engine mounting spacer bolt rear upper side 1 Down tube nut rear side 12 NOTE Tighten the spacer bolts 1 2 3 to specifi cation with a pivot shaft wrench When tigh...

Page 213: ...t upper side 30 temporarily tighten NOTE Do not fully tighten the bolts and nuts 9 Tighten Engine mounting nut front lower side 21 Engine bracket nuts front upper side 23 Engine mounting nut front upper side 22 Engine bracket bolts left upper side 25 Engine mounting bolts left upper side 26 Engine bracket bolts right upper side 28 Engine mounting bolts right upper side 29 and 30 T R Down tube nut ...

Page 214: ...ENGINE REMOVAL 5 15 25 10 11 28 26 12 29 27 14 30 26 24 2 21 19 18 18 19 23 22 20 9 13 ...

Page 215: ...ug 4 2 Timing mark accessing screw 1 3 Crankshaft end cover 1 4 Decompression solenoid cover 1 5 Camshaft sprocket cover 1 6 Camshaft sprocket cover gasket 1 7 Dowel pin 2 For installation reverse the removal procedure LS T R 18 Nm 1 8 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib 4 7 6 5 2 3 1 1 New 6 New New ...

Page 216: ...ead cover bolt 10 l 50 mm 1 97 in 7 Cylinder head cover bolt 12 l 40 mm 1 57 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder head cover gasket 2 11 Dowel pin 4 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New LS LS 7 7 7 7 7 7 7 8 1 1 1 2 2 3 3 4 4 5 5 7 4 6 6 6 6 7 11 6 6 4 6 6 6 6 7 9 10 10 11 11 11...

Page 217: ...in green painting 6 Push rod 2 1 l 290 5 mm 11 437 in yellow painting 7 Rear rocker arm base 1 8 Front rocker arm base 1 9 Rocker arm shaft 4 10 Rocker arm 1 2 11 Rocker arm 2 2 12 Locknut 4 13 Adjusting screw 4 For installation reverse the removal procedure E E E E E E E E E E 12 13 10 12 13 11 9 6 5 7 3 4 4 12 13 10 9 12 13 11 9 5 4 3 New New 1 2 8 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg...

Page 218: ...TONS on page 5 41 1 Push rod cover 2 2 O ring 4 3 Seal 2 4 Rear valve lifter case 1 5 Front valve lifter case 1 6 Valve lifter 4 For installation reverse the removal procedure LT LT LT LT E E E E E E E 2 1 3 2 6 6 4 5 2 1 3 2 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New New New New New New New ...

Page 219: ...gear 1 7 Straight key 1 8 Front cylinder camshaft end cover 1 9 Oil delivery pipe 1 10 Camshaft cover 1 11 Camshaft cover gasket 1 12 Dowel pin 2 13 Front cylinder camshaft 1 14 Rear cylinder camshaft 1 For installation reverse the removal procedure LT LT LT LT 14 11 13 12 12 10 9 6 3 2 7 4 5 8 1 6 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m...

Page 220: ...er arm bases with the rocker arms 3 Remove Valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the correct place CAUTION EC5YU1015 Do not lay the removed valve lifter on its side EAS23830 REMOVING THE CAMSHAFTS 1 Loosen Front cylinder camshaft end cover bolts 1 Camshaft drive gear bolt 2 NOTE Place a folded copper washer 3 between the teeth of the c...

Page 221: ...re fully loosened remove them EAS23860 CHECKING THE CAMSHAFTS 1 Check Cam Blue discoloration pitting scratches Re place the camshaft 2 Measure Cam dimensions a and b Out of specification Replace the camshaft Camshaft lobe dimensions Intake A 38 241 38 341 mm 1 5055 1 5095 in cylinder 1 38 243 38 343 mm 1 5056 1 5096 in cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 ...

Page 222: ...of specification Replace the defective part s NOTE Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter 8 Calculate Camshaft to camshaft cover clearance Out of specification Replace the defective part s Camshaft journal diameter crankcase side 24 942 24 965 mm 0 9820 0 9829 in Camshaft journal diameter camshaft c...

Page 223: ... arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the de fective part s EAS23900 CHECKING THE ROCKER ARM BASES 1 Check Rocker arm base Cracks damage Replace EAS23910 CHECKING THE PUSH RODS...

Page 224: ...e 5 Calculate Valve lifter to valve lifter case clearance NOTE Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm 0 0028 in Replace the defective part s EAS23930 CHECKING THE PUSH ROD COVER 1 Check Push rod cover Cranks damage Replace Seal Valve lifter outside diameter intake 22 962 22 974 mm 0 9040 0 9045 in Valve lifter outside diameter exhaust 22 962 22...

Page 225: ...place EAS24030 INSTALLING THE CAMSHAFTS 1 Install Camshafts to the camshaft cover NOTE Lubricate molybdenum disulfide oil onto the camshaft journals and lobes Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft 2 Install Camshaft cover 1 along with the camshafts Camshaft oil delivery pipe 2 NOTE Tighten the camshaft cover bolts in stages and in...

Page 226: ...n Camshaft drive gear bolt 1 Front cylinder camshaft end cover bolts 2 NOTE Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear After tightening the camshaft drive gear bolt remove the copper washer to clean the teeth of the camshaft drive gear and camshaft ...

Page 227: ...emoved WARNING EWA12880 Be careful since the engine is hot g With piston 1 at TDC count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown When these marks align between the centers of the camshaft drive and driven gears the corresponding valve lifter is at its highest point h Rotate the crankshaft until the mark on the camshaft driven gear for the ...

Page 228: ...dure applies to both cylin ders 1 Install Rocker arms 1 Rocker arm shafts 2 onto rocker arm base NOTE The thread hole a of the rocker arm shaft must face to the outside 2 Install Rocker arm base with rocker arms Push rods a Put the rocker arm base on the cylinder head b Install the push rods NOTE Be sure to correctly install the push rods be tween the rocker arms and valve lifters as shown The ill...

Page 229: ... l 40 mm 1 57 in Bolts 5 l 50 mm 1 97 in Bolt with washer 6 l 50 mm 1 97 in Bolts 7 l 60 mm 2 36 in 2 Install Tappet covers 1 NOTE Install the tappet covers with their UP marks a facing each other A Rear cylinder B Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter 5 Push rod 1 l 288 5 mm 11 358 in 6 Push rod 2 l 290 5 mm 11 437 in T R Ro...

Page 230: ...l pipe 1 1 From crankcase to cylinder heads 4 Copper washer 4 5 Copper washer 2 6 Engine temperature sensor 1 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 For installation reverse the removal procedure E T R 21 Nm 2 1 m kg 15 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 39 Nm 3 9 m kg 28 ft Ib 7 4 4 9 10 3 5...

Page 231: ...ds Valve seats 2 Check Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a f...

Page 232: ...s M10 5 6 NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head nut M12 45 Nm 4 5 m kg 32 ft lb T R Cylinder head nut M10 39 Nm 3 9 m kg 28 ft lb A Front cylinder B Rear cylinder 6 4 2 1 3 5 B ...

Page 233: ...oth cylinders Cylinder heads Refer to CYLINDER HEADS on page 5 31 1 Valve cotter 8 2 Upper spring seat 4 3 Outer valve spring 4 4 Inner valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve stem seal 4 8 Lower spring seat 4 9 Valve guide 4 For installation reverse the removal procedure 5 6 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 M E M E New New New New 9 9 9 9 M M ...

Page 234: ...essing the valve springs with the valve spring compressor set 1 3 Remove Upper spring seat 1 Outer valve spring 2 Inner valve spring 3 Valve 4 Valve stem seal 5 Lower spring seat 6 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve gui...

Page 235: ...guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Valve margin thickness D a Out of specification Replace the valve Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve gu...

Page 236: ...ion Replace the cylinder head 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 NOTE Where the valve seat and valve face contacted one another the blueing will have been re moved 4 Lap Valve face Valve seat NOTE After repla...

Page 237: ...d 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 head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following ...

Page 238: ...b 6 42 7 44 kgf Installed compression spring force exhaust 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Installed length intake 29 00 mm 1 14 in Installed length exhaust 29 00 mm 1 14 in Outer spring Installed compression spring force intake 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed compression spring force exhaust 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed length intake...

Page 239: ... cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 ...

Page 240: ...rks Cylinder head Refer to CYLINDER HEADS on page 5 31 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal procedure 1 3 4 5 7 8 9 10 3 4 6 5 5 7 6 5 8 9 10 2 New New New New New New E E E ...

Page 241: ...g Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston ...

Page 242: ...place the piston and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown Piston Diameter D 96 960 96 975 mm 3 8173 3 8179 in b 10 mm 0 39 in from the bottom edge of the piston Piston to cylinder...

Page 243: ...as a set EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd ring 2 Lower oil ring rail 3 Upper oil ring rail 4 Oil ring expander 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up Piston ring Top ring End gap installed 0 30 0 50 mm 0 01 0 02 in Limit 0 70 mm 0 0276 i...

Page 244: ...ip from falling into the crankcase Reinstall each piston into its original cylinder numbering order starting from the left 1 to 2 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Recommended lubricant Engine oil New a Top ring b Up...

Page 245: ... Air duct Refer to GENERAL CHASSIS on page 4 1 Oil tank Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Crankshaft position sensor coupler 1 Disconnect 2 Shift arm 1 3 Oil tank bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 5 2 3 6 4 5 6 1 New ...

Page 246: ...Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Bearing 1 3 Crankshaft position sensor lead holder 3 4 Crankshaft position sensor 1 For installation reverse the removal procedure 2 1 3 3 3 4 LT LT LT LT LT LT LT LS T R 10 Nm 1 0 m kg 7 2 ft Ib New ...

Page 247: ... Clutch plate 8 8 Conical spring washer 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 2 1 12 Clutch damper spring 1 13 Clutch damper spring seat 1 14 Clutch boss 1 15 Thrust washer 1 1 16 Bearing 1 17 Clutch housing 1 LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T ...

Page 248: ...t position sensor rotor 1 28 Primary drive gear 1 29 Straight key 1 For installation reverse the removal procedure Removing the clutch Order Job Parts to remove Q ty Remarks LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T R 8 Nm 0 8 m kg 5 8 ft Ib ...

Page 249: ...iaphragm holder 1 4 Clutch fluid reservoir diaphragm 1 5 Clutch fluid reservoir 1 6 Clutch fluid reservoir hose 1 7 Left rearview mirror 1 8 Clutch fluid reservoir bracket 1 9 Clutch lever 1 10 Bushing 1 11 Clutch switch coupler 1 Disconnect 12 Clutch switch 1 13 Clutch hose union bolt 1 14 Copper washer 2 15 Clutch hose 1 T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 30 Nm 3 0 m kg...

Page 250: ...linder 1 For installation reverse the removal procedure Removing the clutch master cylinder Order Job Parts to remove Q ty Remarks T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib LS LS New 7 8 1 2 3 4 5 6 9 10 11 12 17 15 16 13 14 ...

Page 251: ...o remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Clutch master cylinder kit 1 3 Dust seal 1 4 Circlip 1 5 Clutch fluid reservoir hose joint 1 6 O ring 1 7 Clutch master cylinder body 1 For assembly reverse the disassembly procedure New New LS New 3 4 5 6 7 2 1 ...

Page 252: ...er to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib New 3 6 2 6 5 4 1 ...

Page 253: ...ob Parts to remove Q ty Remarks 1 Boots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 For assembly reverse the disassembly procedure LS LS 1 2 4 3 5 New T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 254: ... DRIVE GEAR 1 Remove Primary drive gear bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primary drive gear bolt EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction pl...

Page 255: ...eck Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will ...

Page 256: ...and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Apply Sealant onto the crankshaft position sensor lead grommet EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Straight key 1 Primary drive gear 2 Crankshaft position sensor rotor 3 Spacer 4 Primary drive gear bolt ...

Page 257: ...and con ical spring washer mating surfaces with engine oil Install the washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss nut 3 at a cutout b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates NOTE First install a fr...

Page 258: ...r reas sembly Never use solvents on internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 min...

Page 259: ...er a clutch master cylinder is disas sembled replace the piston seals EAS25310 INSTALLING THE CLUTCH MASTER CYLINDER 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 NOTE Align the end of the clutch master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 CAUTI...

Page 260: ... a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal 4 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 6 Check Clutch lever operation Soft or spongy feeling Bleed ...

Page 261: ...r with the specified amount of the recom mended clutch fluid WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When re...

Page 262: ...CLUTCH 5 63 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 a ...

Page 263: ...marks Clutch housing Refer to CLUTCH on page 5 46 1 Shift shaft 1 2 Circlip 2 3 Shift shaft spring 1 4 Shift shaft spring stopper 1 5 Washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation reverse the removal procedure LS LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib 1 3 2 7 6 5 4 New ...

Page 264: ... 1 Install Stopper lever 1 Stopper lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Install the stopper lever spring as shown in the illustration Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft spring 1 Circlips Shift shaft 2 NOTE Lubricate the oil seal lips with lithium soap based ...

Page 265: ...mbly coupler 1 Disconnect 2 Rectifier regulator 1 3 Oil pipe 2 1 From oil pump to generator cover 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil assembly lead holder 1 8 Stator coil assembly 1 For installation reverse the removal procedure LT 9 LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 8 5 4 6 3 7 2 1 6 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m k...

Page 266: ...marks 1 Starter clutch idle gear shaft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 For installation reverse the removal procedure E R 80 Nm 8 0 m kg 58 ft Ib T 2 4 3 1 5 7 6 E E ...

Page 267: ... generator rotor b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should 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 EAS24510 INSTALLING THE GENERATOR 1 Install Woodruff key Generator r...

Page 268: ...generator rotor bolt 1 while holding the generator rotor 2 with a sheave holder 3 3 Apply Sealant onto the stator coil assembly lead grommet T R Generator rotor bolt 80 Nm 8 0 m kg 58 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 2 3 1 ...

Page 269: ...CTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Oil tank Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal procedure 2 1 ...

Page 270: ...over 1 4 Bearing 1 5 Oil seal 1 6 Circlip 1 7 Starter motor front cover 1 8 Brush 2 9 Brush holder along with the brushes 1 10 Brush seat along with the brushes 1 11 Bearing 1 12 Gasket 2 13 Armature assembly 1 14 Starter motor yoke 1 For assembly reverse the disassembly procedure 8 4 5 7 3 2 1 6 LS New New New New New New 12 11 12 10 9 14 13 New LS ...

Page 271: ...commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 5 mm 1 08 in Mica un...

Page 272: ... the slot a on the brush seat with the tab b in the starter motor front cover 2 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 3 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor rear cover b a 1 1 b a 3...

Page 273: ...5 16 Pistons Refer to CYLINDERS AND PISTONS on page 5 41 Shift shaft Refer to SHIFT SHAFT on page 5 64 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 66 1 Speed sensor 1 2 Oil filter cartridge bracket 1 3 Generator shaft end cover 1 4 Oil delivery pipe 2 1 5 Oil pump driven gear stopper 1 6 Oil pump driven gear 1 7 Left crankcase 1 8 Dowel pin 2 9 Joint pipe 1 ...

Page 274: ...CRANKCASE 5 75 10 Right crankcase 1 For installation reverse the removal procedure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 275: ...ve Q ty Remarks Oil pump Refer to OIL PUMP on page 5 81 Crankshaft Refer to CRANKSHAFT on page 5 86 Transmission Refer to TRANSMISSION on page 5 92 1 Oil baffle plate 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 1 5 Bearing 4 For installation reverse the removal procedure ...

Page 276: ... to the numbers in the illustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence M8 100 mm bolts 1 2 M8 80 mm bolt 3 M6 105 mm bolt 21 M6 85 mm bolt 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 3 Turn Shift drum segment NOTE Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segme...

Page 277: ...L PIPE 1 Check Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS25610 CHECKING THE OIL PUMP DRIVE 1 Check Oil pump drive gear Oil pump driven gear Chips pitting roughness wear Replace the defective part s ET5YU1023 INSTALLING THE BEARING RETAINER 1 Install Bearing retainer 1 NOTE Install the bearing retainer 1 with its OUT mark a facing outward Apply locking agent LOCT...

Page 278: ...s 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 5 Apply Engine oil onto the crankshaft pins bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair 7 Install Generator shaft bolt 1 NOTE While the holding the generator rotor 2 with the primary sheave holder 3 tighten the generator shaft bolt T R Crankcase bolt M8 24 Nm 2 4 m k...

Page 279: ...CRANKCASE 5 80 ...

Page 280: ...910 OIL PUMP Removing the oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Oil strainer crankcase 1 2 Oil pump assembly 1 For installation reverse the removal procedure ...

Page 281: ...tainer 1 2 Spring 1 3 Relief valve 1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Collar 1 8 Ball 1 9 Oil pump outer rotor 1 1 10 Oil pump inner rotor 1 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Pin 2 14 Oil pump shaft 1 15 Pin 1 16 Oil pump inner rotor 2 1 17 Oil pump outer rotor 2 1 ...

Page 282: ...OIL PUMP 5 83 18 Oil seal 2 19 Oil pump housing 1 For assembly reverse the disassembly procedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks ...

Page 283: ...ll Collar Spring Oil seal Damage wear Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer crankcase Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump housing 1 Oil seal 2 Oil pump outer rotor 2 3 Oil pump inner rotor 2 4 Pin 5 Inner rot...

Page 284: ... pin in the oil pump shaft with the groove in the inner ro tor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 84 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump housing cover 2 screw 2 Nm 0 2 m kg 1 4 ft lb T R Oil pump housing cover 1 screw 2 Nm 0 2 m kg 1 4 ft lb T R Spring r...

Page 285: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal procedure ...

Page 286: ...in to big end bearing clearance Out of specification Replace the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big en...

Page 287: ...ocedure f Tighten the connecting rod bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specified angle 120 150 WARNING EWA12900 When the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure...

Page 288: ...s 5 Measure Crankshaft journal diameter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside diameter a Out of specification Replace the crank case assembly NOTE Measure the inside diameter of each crankshaft journal bearing at two places P1 P2 a P1 connecting rod P crankshaft 5 2 3 brown Beari...

Page 289: ... Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projections c on the connect ing rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod bolts 1...

Page 290: ...torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is the specified an gle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly CAUTION ECA13970 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Make sure that the generator sh...

Page 291: ...orks Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork L 1 4 Shift fork R 1 5 Shift fork C 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation reverse the removal procedure ...

Page 292: ...der Job Parts to remove Q ty Remarks 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 Collar 1 5 Washer 1 6 2nd 3rd pinion gear 1 7 Circlip 1 8 Washer 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 293: ...y Remarks 1 5th wheel gear 1 2 Circlip 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 Circlip 1 7 Washer 1 8 1st wheel gear 1 9 Collar 1 10 Washer 1 11 4th wheel gear 1 12 Circlip 1 13 Washer 1 14 3rd wheel gear 1 15 Collar 1 16 Drive axle 1 For assembly reverse the disassembly procedure ...

Page 294: ...ar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace...

Page 295: ... Washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Shift fork R 1 Shift fork C 2 Shift fork L 3 Shift drum assembly 4 Shift fork guide bars 5 NOTE The embossed ...

Page 296: ...FUEL 6 ...

Page 297: ...2 INSTALLING THE FUEL TANK 6 2 THROTTLE BODIES 6 4 CHECKING THE INJECTORS 6 9 CHECKING THE THROTTLE BODIES 6 9 CHECKING THE ROLLOVER VALVES 6 9 CHECKING THE PRESSURE REGULATOR 6 9 CHECKING THE PRESSURE REGULATOR OPERATION 6 9 ADJUSTING THE THROTTLE POSITION SENSOR 6 10 INSTALLING THE FUEL PIPE 6 10 ISC IDLE SPEED CONTROL UNIT 6 11 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 6 13 ...

Page 298: ......

Page 299: ...cover 1 2 Fuel pump coupler 1 Disconnect 3 Fuel sender coupler 1 Disconnect 4 Fuel tank overflow hose 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Fuel hose 1 Disconnect 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal procedure 7 4 3 2 5 6 9 8 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib 6 New ...

Page 300: ... wall or the like EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly 2 Check Diaphragms and gaskets Tears fatigue cracks Replace fuel pump assembly EAS26690 CHECK...

Page 301: ...hose connector cover on the fuel hose is in the correct posi tion otherwise the fuel hose will not be prop erly installed NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 ...

Page 302: ... to pressure regulator 1 Disconnect 3 Pressure regulator 1 4 Fuel return hose 1 5 Fuel pipe holder 2 6 Fuel return hose fuel return pipe to fuel pump 1 7 Fuel return pipe 1 8 Fuel tank breather hose 1 9 Fuel tank overflow hose 1 10 Fuel tank breather overflow hose holder 1 11 Fuel tank breather overflow hose 1 12 Rollover valve hose 4 13 Rollover valve 1 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 ...

Page 303: ...1 For installation reverse the removal procedure Removing the pressure regulator and rollover valves Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib 6 7 5 5 10 8 9 13 15 14 12 12 12 12 11 2 4 3 1 ...

Page 304: ... 1 Disconnect 3 Cylinder 2 intake air pressure sensor hose 1 Disconnect 4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 Throttle cable 2 Disconnect 6 Throttle body joint clamp screw 2 Loosen 7 Throttle body 1 CAUTION EC5YU1030 The throttle body should not be disassembled 8 Throttle position sensor 1 For installation reverse the removal procedure LS 5 7 8 6 6 3 1 4 2 T R...

Page 305: ...regulator 1 3 Cylinder 2 ISC idle speed control unit outlet hose 1 4 Cylinder 1 ISC idle speed control unit outlet hose 1 5 Intake manifold assembly 1 6 Cylinder 2 injector coupler 1 Disconnect 7 Cylinder 1 injector coupler 1 Disconnect 8 Gasket 2 For installation reverse the removal procedure 3 4 6 7 8 5 8 1 2 T R 10 Nm 1 0 m kg 7 2 ft Ib New New 2 2 ...

Page 306: ... Remarks 1 Fuel pipe 1 2 Injector joint 1 1 3 Injector joint 2 1 4 Injector 2 5 Intake manifold 2 For installation reverse the removal procedure 2 4 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib New New New New New New New New 5 5 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib ...

Page 307: ...r valves must be in an upright posi tion when checking the airflow EAS27000 CHECKING THE PRESSURE REGULATOR 1 Check Pressure regulator Damage Replace EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1 Check Pressure regulator operation a Remove the pressure regulator cover Refer to THROTTLE BODIES on page 6 4 b Disconnect the fuel hose 1 from the pres sure regulator 2 c Connect the fuel pressure...

Page 308: ...e throttle position sensor coupler c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 ET5YU1016 INSTALLING THE FUEL PIPE 1 Install Fuel pipe 1 NOTE Install the fuel pipe 1 so that it contacts the pro jections a...

Page 309: ...2 Surge tank 1 3 Surge tank hose 1 4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 One way valve 1 6 Intake solenoid vacuum hose intake solenoid to one way valve 1 7 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 8 Intake solenoid coupler 1 Disconnect 9 Intake solenoid 1 10 Intake solenoid holder 1 11 Intake solenoid bracket 1 13 12 14 16 15 9 10...

Page 310: ...ontrol unit outlet hose 1 Disconnect 15 ISC idle speed control unit inlet hose 1 16 ISC idle speed control unit 1 For installation reverse the removal procedure Removing the ISC idle speed control unit and intake solenoid Order Job Parts to remove Q ty Remarks 13 12 14 16 15 9 10 2 1 3 11 6 5 4 8 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib ...

Page 311: ...ck Hoses Loose connections Connect properly Cracks damage Replace 2 Check Surge tank Cracks damage Replace 3 Check One way valve Cracks damage faulty Replace NOTE Check that air flows smoothly only in the direc tion of the arrow shown in the illustration 4 Check Intake solenoid Damage Replace ...

Page 312: ......

Page 313: ...ELEC 7 ...

Page 314: ...AGRAM 7 19 TROUBLESHOOTING 7 21 FUEL INJECTION SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 ECU SELF DIAGNOSTIC FUNCTION 7 27 SELF DIAGNOSTIC FUNCTION TABLE 7 28 TROUBLESHOOTING METHOD 7 31 DIAGNOSTIC MODE 7 31 TROUBLESHOOTING DETAILS 7 39 FUEL PUMP SYSTEM 7 67 CIRCUIT DIAGRAM 7 67 TROUBLESHOOTING 7 69 MUFFLER COOLING SYSTEM 7 71 CIRCUIT DIAGRAM 7 71 TROUBLESHOOTING 7 73 IMMOBILIZER SYSTEM 7 75 CIRCUIT DIAGRA...

Page 315: ...ING THE LEAN ANGLE CUT OFF SWITCH 7 100 CHECKING THE STATOR COIL 7 101 CHECKING THE RECTIFIER REGULATOR 7 101 CHECKING THE HORN 7 102 CHECKING THE ENGINE TEMPERATURE SENSOR 7 102 CHECKING THE FUEL SENDER 7 103 CHECKING THE SPEED SENSOR 7 103 CHECKING THE THROTTLE POSITION SENSOR 7 104 CHECKING THE FUEL PUMP 7 104 CHECKING THE EXUP SERVO MOTOR 7 105 CHECKING THE DECOMPRESSION SOLENOID 7 105 CHECKIN...

Page 316: ...R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y BLACK B L L Y BLACK L B Sb B Sb Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W R W Y Br Y Br W L Br B L L Y L W Gy R B R Gy W B R B R W R B G B R B L L Lg Dg Ch L B G Y L R G...

Page 317: ...ral switch 19 Sidestand switch 20 Crankshaft position sensor 24 Lean angle cut off switch 29 ECU electronic control unit 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 56 Clutch switch 73 Engine stop switch 81 Ignition fuse ...

Page 318: ... page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNITION SPARK GAP on page 7 100 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7 99 Replace the spark plug cap s 6 Check ...

Page 319: ... on page 7 89 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 14 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the relay unit 15 Check the lean angle cut off swi...

Page 320: ... WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B...

Page 321: ...rter motor 8 Main fuse 10 ECU fuse 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 19 Sidestand switch 29 ECU electronic control unit 38 Decompression solenoid 56 Clutch switch 70 Auto decompression fuse 73 Engine stop switch 74 Start switch 81 Ignition fuse ...

Page 322: ...ulled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has bee...

Page 323: ...EBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 ECU fuse 15 Auto decompression fuse 16 Decompression solenoid 17 ECU electronic control unit ...

Page 324: ...RY on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 72 Repair or replace the starter motor 4 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 5 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the r...

Page 325: ... on page 7 89 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 13 Check the decompression solenoid Refer to CHECKING THE DECOMPRESSION SOLENOID on page 7 105 Replace the decompression solenoid 14 Check the entire start...

Page 326: ...ACK BLACK BLACK Br B B L B L P Y L Y G B L Y G L Y Y D B B B L L D Br Br Br B D R R Br Br L Br R Br G R Gy R R R R R R B Br W B B R R R B B R W R W R L L B BB3 BB2 BB1 BB4 B B B B B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R L B B B B Y Br R Br L B2 B L Gy1 B R G R G Y L R W Lg B2 Sb W R L L W1 L Y L G ...

Page 327: ...CHARGING SYSTEM 7 12 1 AC magneto 2 Rectifier regulator 4 Battery 8 Main fuse ...

Page 328: ...o CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 101 Replace the stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTIFIER REGULATOR on page 7 101 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM on p...

Page 329: ...CHARGING SYSTEM 7 14 ...

Page 330: ...RE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R...

Page 331: ...ic control unit 47 High beam indicator light 50 Meter light 54 Headlight relay 57 Pass switch 58 Dimmer switch 67 Auxiliary light 68 Headlight high beam 69 Headlight low beam 75 Tail brake light 76 License plate light 80 Headlight fuse 82 Signaling system fuse 83 Parking lighting fuse ...

Page 332: ...bulb socket s 2 Check the fuses Main headlight signaling system parking lighting and ECU Refer to CHECKING THE FUSES on page 7 93 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 5 Chec...

Page 333: ...LIGHTING SYSTEM 7 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 15 Properly connect or repair the lighting system wiring This circuit is OK ...

Page 334: ...IRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb ...

Page 335: ...i function meter 45 Engine trouble warning light 48 Left turn signal indicator light 49 Right turn signal indicator light 52 Horn 53 Turn signal hazard relay 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 Rear right turn signal light 65 Rear left turn signal light 72 Front brake light switch 75 Tail brake light 77 Rear brak...

Page 336: ...S on page 7 93 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling...

Page 337: ...WITCHES on page 7 89 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 92 Replace the turn signal light bulb socket or both 2 Check the turn signal switch R...

Page 338: ...re signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 7 103 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 C...

Page 339: ...SIGNALING SYSTEM 7 24 ...

Page 340: ...SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb ...

Page 341: ...Speed sensor 26 Muffler cooling fan temperature sensor 27 Air temperature sensor 28 Engine temperature sensor 29 ECU electronic control unit 30 ISC idle speed control unit 31 Intake solenoid 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 37 EXUP servo motor 38 Decompression solenoid 39 Injector 1 4...

Page 342: ...tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light bulb The engine trouble warning light comes on for 1 4 s...

Page 343: ...mptom Able un able to start Able un able to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor Unable Unable 13 Cylinder 1 intake air pressure sensor open or short circuit Cylinder 1 intake air pressure sensor open or short circuit detected Able Able 14 Cylinder 1 intake air pressure sensor hose line Cylinder 1 intake air pressure sensor hose sys...

Page 344: ...rs Able depending on the number of faulty cylin ders 34 Cylinder 2 left ignition coil faulty ignition Malfunction detected in the primary wire of the cylinder 2 left ignition coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 35 Cylinder 1 left or right ignition coil faulty ignition Malfunction detected in the primary wire of the cylinder 1 lef...

Page 345: ...meter Unable Unable 62 Muffler cooling fan temperature sensor open or short circuit Muffler cooling fan temperature sensor open or short circuit detected Able Able 63 Muffler cooling fan temperature sensor ambient temperature abnormally high Engine trouble warning light is flashing Abnormally high temperature is detected by muffler cooling fan temperature sensor Able Able Fault code No Item Sympto...

Page 346: ...trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27420 DIAGNOSTIC MODE ...

Page 347: ...ess the SELECT button Press the SELECT button for 1 second or longer to automatically increase the diagnostic code numbers 8 Verify the operation of the sensor or actuator Sensor operation The data representing the operating conditions of the sensor appears on the odometer trip meter fu el reserve trip meter LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the e...

Page 348: ...tive air temperature sensor Malfunction in ECU Improperly installed air temperature sensor 05 24 No normal signal is received from the O2 sensor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed sensor 25 Cylinder 2 intake air pressure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 2 intake air pressure...

Page 349: ...ystem 30 32 36 Malfunction detected in the primary wire of the cylinder 2 right ignition coil Open or short circuit in wire harness Malfunction in cylinder 2 right ignition coil Malfunction in ECU Malfunction in a component of ignition cut off circuit system 33 37 Engine speed is high when the engine is idling Open circuit in wire harness Malfunction in throttle body Malfunction in throttle cables...

Page 350: ...the internal memory 62 Muffler cooling fan temperature sensor open or short circuit detected Open or short circuit in wire harness Defective muffler cooling fan temperature sensor Malfunction in ECU Improperly installed sensor 12 63 Engine trouble warning light is flashing Abnormally high temperature is detected by muffler cooling fan temperature sensor Muffler cover fan fuse or ECU fuse is blown ...

Page 351: ... intake air pressure Displays the cylinder 2 intake air pressure Set the engine stop switch to then operate the throttle while pushing the start switch If the display value changes the performance is OK 05 Air temperature Displays the air temperature Compare the actually measured air temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number increases when the rear...

Page 352: ... operating angle Engine trouble warning light comes on twice once when the EXUP valve is closing and once when it is opening 60 EEPROM fault code display No history 00 History exists 01 or 02 Cylinder fault code If both cylinders are defective the display alternates every two seconds 61 Malfunction history code display No history 00 History exists Fault codes 12 63 If more than one code number is ...

Page 353: ...left or right ignition coil Actuates the cylinder 1 left or right ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ignition checker 33 Cylinder 2 right ignition coil Actuates the cylinder 2 right ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ign...

Page 354: ... the engine trouble warning light Check the operating sound of the muffler cooling fan motor relay five times 52 Headlight relay Actuates the headlight relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trouble warning light Check the operating sound of the headlight relay five times 54 ISC valve Actuates and fully closes the ISC valve then opens it to the stan...

Page 355: ...thod 1 Installed condition of crankshaft position sensor Check for looseness or pinching Cranking the engine 2 Connections Crankshaft position sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair...

Page 356: ...ler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler black blue black blue pink white pink white blue blue...

Page 357: ...tarting the engine and operating it at idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connection Replace it if there is a malfunction 3 Connections Cylinder 1 intake air pressure sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is...

Page 358: ...be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler blue blue yellow yellow back black 4 Throttle position sensor lead wire open circuit output voltage check ...

Page 359: ...Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 7 105 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking conditio...

Page 360: ...place if defective Refer to CHECKING THE SWITCHES on page 7 89 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of air temperature sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Ai...

Page 361: ...sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler gray white gray white red blue red blue gray green g...

Page 362: ...er for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler black blue black blue pink yellow pink yellow blue blu...

Page 363: ...tarting the engine and operating it at idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connection Replace it if there is a malfunction 3 Connections Cylinder 2 intake air pressure sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is...

Page 364: ...ensor coupler Main wire harness ECU coupler Sub wire harness 2 coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between engine temperature sensor coupler and ECU co...

Page 365: ...e 4 Defective decompression solenoid thermistor Execute the diagnostic mode Code No 55 Replace if defective Refer to CHECKING THE DECOMPRESSION SOLENOID on page 7 105 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle cut off switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Raise the vehicle...

Page 366: ... for any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wir...

Page 367: ...ns that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 left ignition coil connector and ECU coupler main wire harness black red blue red gray re...

Page 368: ... for any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wir...

Page 369: ...s that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 right ignition coil connector and ECU coupler main wire harness black red blue red gray bl...

Page 370: ...LAY on page 3 7 3 ISC valve is stuck fully open due to disconnected ISC unit hose or coupler High engine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Check that the ISC unit hose is not disconnected Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does n...

Page 371: ... harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between decompression solenoid coupler and ECU coupler light green light green Between decompression solenoid coupler ...

Page 372: ...r any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle cut off switch coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean...

Page 373: ...condition of the coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by operating the vehicle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue...

Page 374: ...tween neutral switch coupler and fuel pump relay coupler sky blue sky blue Between fuel pump relay coupler and ECU coupler blue yellow blue yellow B 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION on page 5 92 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 7 89 Fault code No 42 Sy...

Page 375: ... relay coupler and ECU coupler blue red blue red red blue red blue Between fuel pump relay coupler and battery terminal red red Between fuel pump relay coupler and engine stop switch coupler black red black red 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code N...

Page 376: ... THE BATTERY on page 7 94 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYSTEM on page 7 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch red red Between main switch and ignition fuse brown blue brown blue Between ignition fuse and ECU red white red white Fault code No 50 Symptom Faulty E...

Page 377: ... fan temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between muffler cooling fan temperature sensor coupler and ECU coupler black ...

Page 378: ...ge 7 96 3 Positions of muffler cooling fan temperature sensor and its surrounding parts changed due to deformed parts near sensor Muffler cooling fan temperature sensor detected a temperature of 120 C 248 F or higher Check that the parts near the muffler cooling fan temperature sensor are not deformed and that the sensor and its surrounding parts are in their correct positions Repair or replace if...

Page 379: ...pler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the ...

Page 380: ...ter assembly coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly coupler and ECU coupler yellow blue yellow blue 3 Malfunction in ...

Page 381: ...FUEL INJECTION SYSTEM 7 66 ...

Page 382: ...G R Gy R R R R R R B Br W B B R R R B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W Lg Dg Ch L G R G R L B L R W Gy G Gy W B B W L R L Gy W Gy G ...

Page 383: ...FUEL PUMP SYSTEM 7 68 3 Main switch 4 Battery 5 Fuel injection system fuse 8 Main fuse 10 ECU fuse 15 Fuel pump relay 17 Fuel pump 29 ECU electronic control unit 73 Engine stop switch 81 Ignition fuse ...

Page 384: ...n the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 6 Check the fuel pump...

Page 385: ...FUEL PUMP SYSTEM 7 70 ...

Page 386: ...r L Br L R B G Y R W Br R Br G R Gy R R R R R R B Br W B B R R R B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W R L Gy G B B W L R L Gy W Gy G B...

Page 387: ...LING SYSTEM 7 72 4 Battery 8 Main fuse 9 Muffler cover fan fuse 10 ECU fuse 26 Muffler cooling fan temperature sensor 29 ECU electronic control unit 78 Muffler cooling fan motor 79 Muffler cooling fan motor relay ...

Page 388: ...place the battery 3 Check the muffler cooling fan motor Refer to CHECKING THE MUFFLER COOLING FAN MOTOR on page 7 107 Replace the muffler cooling fan motor 4 Check the muffler cooling fan motor relay Refer to CHECKING THE RELAYS on page 7 96 Replace the muffler cooling fan motor relay 5 Check the muffler cooling fan temperature sensor Refer to CHECKING THE MUFFLER COOLING FAN TEMPERATURE SENSOR on...

Page 389: ...MUFFLER COOLING SYSTEM 7 74 ...

Page 390: ... WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W S...

Page 391: ...Main switch 4 Battery 8 Main fuse 10 ECU fuse 11 Immobilizer unit 12 Backup fuse odometer clock and immobilizer system 29 ECU electronic control unit 44 Multi function meter 46 Immobilizer system indicator light 81 Ignition fuse ...

Page 392: ...ey is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe plac...

Page 393: ...Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Ac...

Page 394: ...ch then turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert t...

Page 395: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 396: ...ery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire immobilizer system wiring Refer to CIRCUIT DIAGRAM on page 7 75 Properly connect or repair the immobilizer system wiring Check the condition of the each immobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 7 81 Fault code Part Symptom Caus...

Page 397: ...nction 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead cable 1 Interference due to radio wave noise 2 Disconnected communication harness 3 Immobilizer unit malfunction 4 ECU failure The ECU or immo...

Page 398: ...IMMOBILIZER SYSTEM 7 83 Example fault code 52 a b a Light on b Light off ...

Page 399: ...IMMOBILIZER SYSTEM 7 84 ...

Page 400: ...ELECTRICAL COMPONENTS 7 85 EAS27970 ELECTRICAL COMPONENTS 4 3 5 7 6 8 9 10 12 13 14 15 1 2 11 ...

Page 401: ...tion coil 4 ISC idle speed control unit 5 Intake solenoid 6 Cylinder 1 right ignition coil 7 Cylinder 1 left ignition coil 8 Muffler cooling fan temperature sensor 9 Muffler cooling fan motor 10 Speed sensor 11 Rear brake light switch 12 Neutral switch 13 Decompression solenoid 14 Rectifier regulator 15 Horn ...

Page 402: ...ELECTRICAL COMPONENTS 7 87 3 4 6 5 8 7 9 11 12 13 14 15 16 17 18 1 2 10 ...

Page 403: ...ttle position sensor 5 Main fuse 6 Fuse box 7 Muffler cooling fan motor relay 8 ECU electronic control unit 9 Headlight relay 10 Relay unit 11 Turn signal hazard relay 12 Fuel injection system fuse 13 Starter relay 14 Lean angle cut off switch 15 Battery 16 EXUP servo motor 17 Crankshaft position sensor 18 Engine temperature sensor ...

Page 404: ...NG THE SWITCHES Br W B L B R Y B Y P G Y B Dg Ch B B BLACK R W L W R B B B Y B BLUE BROWN B B BLUE B B B B B 11 12 13 8 5 6 9 10 1 2 7 3 B B R Y Y Y L B G Dg Br W Ch Dg Br W Ch P B Y B B R W R B L W B Y R Br L Br R 4 R Br L Br R ON OFF L W B Y ...

Page 405: ...nt brake light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Neutral switch 6 Sidestand switch 7 Rear brake light switch 8 Hazard switch 9 Turn signal switch 10 Horn switch 11 Clutch switch 12 Pass switch 13 Dimmer switch ...

Page 406: ...range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch positi...

Page 407: ...e condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW5YU1009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC5YU1020 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touc...

Page 408: ... 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the elec...

Page 409: ...move the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged as ex plained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considera...

Page 410: ...n MF battery stabi lizes about 30 minutes after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage Charging method using a variable current voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat ter...

Page 411: ... Battery leads to the battery terminals CAUTION ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the ...

Page 412: ...e Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 R Y G L R Y Y B 1 2 3 4 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Re...

Page 413: ...Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 ...

Page 414: ...e igni tion coils 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket teste...

Page 415: ...isfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE ...

Page 416: ...e pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the rectifi er regulator Lean angle cut off switch output voltage Less than 65 0 4 1 4 V More than 65 3 7 4 4 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe yellow green 1 Nega...

Page 417: ...ing screw in direction a or b until the horn sound is obtained EAS28210 CHECKING THE ENGINE TEMPERATURE SENSOR 1 Remove Engine temperature sensor from the front cylinder head WARNING EWA14140 Handle the engine temperature sensor with special care Never subject the engine temperature sen sor to strong shocks If the engine temper ature sensor is dropped replace it 2 Check Engine temperature sensor r...

Page 418: ...sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 1k to the fuel sender terminal as shown b Measure the fuel sender resistance EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog...

Page 419: ...Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 6 10 EAS28350 CHECKING THE FUEL PUMP WARNING EWA13850 Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do acciden...

Page 420: ... directions a and b CAUTION EC5YU1023 To prevent damaging the EXUP servo motor perform this test within a few seconds of connecting the battery EAS28400 CHECKING THE DECOMPRESSION SOLENOID 1 Check Decompression solenoid thermistor resis tance Out of specification Replace NOTE The resistance value for the thermistor changes when the temperature changes therefore mea sure the decompression solenoid ...

Page 421: ...e sensors 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown b Turn the main switch to ON c Measure the intake air pressure sensor out put voltage Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green 1 Negative tester probe green 2 Decompression solen...

Page 422: ...air temperature sensor resis tance ET5YU1008 CHECKING THE INTAKE SOLENOID 1 Check Intake solenoid resistance Out of specification Replace a Disconnect the intake solenoid coupler from the intake solenoid b Connect the pocket tester Ω 10 to the in take solenoid terminal as shown c Measure the intake solenoid resistance ET5YU1005 CHECKING THE MUFFLER COOLING FAN MOTOR 1 Check Muffler cooling fan mot...

Page 423: ...ace a Connect the pocket tester Ω 1k to the muf fler cooling fan temperature sensor terminal as shown b Immerse the muffler cooling fan temperature sensor 3 in a container filled with water 4 NOTE Make sure that the muffler cooling fan tempera ture sensor terminals do not get wet c Place a thermometer 5 in the water d Slowly heat the water then let it cool down to the specified temperature e Measu...

Page 424: ...TRBL SHTG 8 ...

Page 425: ...ENGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 426: ......

Page 427: ...Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spar...

Page 428: ... guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assem...

Page 429: ... or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem ...

Page 430: ... Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signa...

Page 431: ...m indicator light 47 High beam indicator light 48 Left turn signal indicator light 49 Right turn signal indicator light 50 Meter light 51 O2 sensor 52 Horn 53 Turn signal hazard relay 54 Headlight relay 55 Left handlebar switch 56 Clutch switch 57 Pass switch 58 Dimmer switch 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 R...

Page 432: ...Y Blue Yellow P L Pink Blue P W Pink White P Y Pink Yellow R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue ...

Page 433: ......

Page 434: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 435: ...W R B B B Y B BLUE Y L W1 B R R W Br Y L B L Y B L Y B Br L L B Br L Br L Br L R B G Y R W Br R Br G R Gy R R R B R R R B Br W B B R R R B B R W R W R L L B O O B R O O B R A WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L...

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