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CONNECTING RODS AND PISTONS

5-83

EAS26030

REMOVING THE CONNECTING RODS AND
PISTONS

The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:

• Connecting rod cap “1”

NOTE:

Identify the position of each connecting rod so
that it can be reinstalled in its original place.

2. Remove:

• Big end bearings

(from the connecting rods and connecting rod
caps)

NOTE:

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

3. Remove:

• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
• Connecting rod “4”

CAUTION:

ECA13810

Do not use a hammer to drive the piston pin
out.

NOTE:

• For reference during installation, put an identi-

fication mark on each piston crown.

• Before removing the piston pin, deburr the pis-

ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “5”.

4. Remove:

• Top ring
• 2nd ring
• 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-to-cylinder clearance

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Measure cylinder bore “C” with the cylinder

bore gauge.

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

1

3

2

4

1

1

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Summary of Contents for 2006 FJR1300A

Page 1: ...2006 SERVICE MANUAL FJR1300A V 3P6 28197 E0 ...

Page 2: ...00A V 2006 SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition January 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ... models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable 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 A...

Page 4: ...ub 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 instruction ch...

Page 5: ... 14 15 16 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 ...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ... 5 ABS COMPONENT FUNCTIONS 1 10 ABS OPERATION 1 16 ABS SELF DIAGNOSIS FUNCTION 1 20 ABS WARNING LIGHT AND OPERATION 1 22 INSTRUMENT FUNCTIONS 1 24 IMPORTANT INFORMATION 1 30 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 30 REPLACEMENT PARTS 1 30 GASKETS OIL SEALS AND O RINGS 1 30 LOCK WASHERS PLATES AND COTTER PINS 1 30 BEARINGS AND OIL SEALS 1 31 CIRCLIPS 1 31 CHECKING THE CONNECTIONS 1 32 SPECIAL TO...

Page 10: ...AS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 11: ...s necessary to control the air fuel ratio in a more precise and finely tuned manner To accom 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 ...

Page 12: ...ed by the ECU Signals that are input from the throttle position sensor coolant temperature sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position se...

Page 13: ...ted The brake line from the rear brake master cylinder is split at the hydraulic unit to transmit brake fluid pressure to both the rear brake caliper and part of the right front brake caliper in the unified brake system The brake fluid pressure transmitted to the rear brake caliper and part of the right front brake caliper is controlled by the proportioning valve and metering valve respectively Th...

Page 14: ...e between the right front brake caliper and the rear brake caliper in the uni fied brake system is determined mechanically be sure to use the specified brake pads Each set of brake pads should be checked individually and replaced if necessary ET3P61019 OUTLINE OF THE ABS 1 The Yamaha ABS anti lock brake system features an electronic control system which acts on the front and rear brakes independen...

Page 15: ...d However the chassis travels forward by its inertia even though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering 4 5 6 7 8 9 10 11 12 13 14 1 2 3 A ...

Page 16: ... closely related to wheel slippage Wheel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keeping the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road surfac es ...

Page 17: ...ake lever and brake pedal independently NOTE When the ABS is activated a pulsating action may be felt at the brake lever or brake pedal but this does not indicate a malfunction The higher the side force on a tire the less traction there is available for braking This is true whether the vehicle is equipped with ABS or not Therefore sudden braking while cornering is not recommend ed Excessive side f...

Page 18: ...ctronic technology The ABS control is processed with good response under various vehicle travel conditions The ABS also includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly comes on The ABS stores the malfunction codes in the memory ...

Page 19: ...nd are in stalled close to the wheel sensors As the distance changes between the top and bottom of the serra tions with the rotation of the wheels inductive electromotive force is generated in the wheel sensors Wheel speed is detected based on the frequency of this alternating voltage 1 8 7 7 6 5 4 2 5 6 7 3 13 14 15 16 12 11 10 9 1 Rear brake master cylinder 2 Hydraulic unit 3 Front brake master ...

Page 20: ... occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on for 2 seconds then goes off Hydraulic unit The hydraulic unit 1 is composed of three hydraulic control valves each with a solenoid valve and flow control valve two buffer chambers two hydraulic pumps and an ABS motor The hydraulic unit adjusts the front and rear wheel brake fluid press...

Page 21: ...er supplied from the ABS ECU signals to decrease the brake fluid pressure and the spool 3 of the flow control valve is moved toward the solenoid valve 3 When the ABS ECU stops transmitting signals to decrease the brake fluid pressure the solenoid valve 2 closes and the brake fluid is pressurized again Pressurizing the brake fluid again while the ABS is activated limits the flow of the brake fluid ...

Page 22: ...ent To protect the ABS ECU from water damage it is protected by a cover 2 As shown in the block following diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits 1 Buffer chamber pressurized 2 Buffer chamber depressurized 3 Raised piston 1 2 1 ...

Page 23: ...NOTE Some types of malfunctions are not recorded in the memory of the ABS ECU e g a drop in battery voltage 7 4 5 6 2 3 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS fuse 7 ABS motor fuse 8 Front brake light switch 9 Brake light relay 10 Tail brake light 11 Rear brake light switch 12 ABS ECU 13 ABS motor ...

Page 24: ...r relay is activated by signals transmitted from the ABS ECU and the ABS motor oper ates when the ABS starts to reduce the hydraulic pressure of the brake fluid 2 1 3 4 5 6 7 8 A 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operation 8 Depressurize pressurize A 8 1000th of a second 1 ...

Page 25: ... for the front wheel only excluding the unified brake system 12 14 1 11 10 2 3 4 5 6 7 8 9 13 1 ABS ECU 2 Pump motor monitor 3 Power supply 4 Pump motor relay coil 5 Power supply 6 Front brake solenoid 7 Rear brake solenoid 8 Unified brake system solenoid 9 ABS warning light 10 Battery 11 ABS motor relay 12 Hydraulic unit 13 ABS motor 14 Solenoid valves ...

Page 26: ...the inlet and outlet check valves of the hydraulic pump are closed preventing the brake fluid from flowing through the pump As a result the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper re turns to the brake master cylinder via port A and port B 1 Brake master cylinder 2 Brake light switch 3 ...

Page 27: ...and the brake fluid is sent to the brake caliper via port C 13 and to the buffer chamber via port D 11 As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 F...

Page 28: ... C 13 At this time the brake is pressurized at a constant rate regardless of the brake fluid pressure level since the restriction of port A 7 chang es so that a constant pressure difference is maintained between chamber A 20 and chamber B 21 of the flow control valve 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 P...

Page 29: ...en goes off if there are no problems 2 The ABS warning light comes on while the start switch is being pushed When the engine is being started the ABS warning light comes on while the start switch is being pushed Refer to ELECTRIC STARTING SYSTEM on page 8 9 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f ABS self diagnosis b c d e a f i ...

Page 30: ... adapter con nected to the ABS test coupler 5 The ABS warning light 1 flashes and a malfunction code 2 is indicated on the multi function dis play when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS The ABS test coupler can be accessed by removing front cowling right inner panel 1 When the test coupler adapter is connected to the ABS test coupler the ...

Page 31: ...on is normal if the ABS warning light comes on for 2 seconds then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained ABS function When hydraulic control is performed by the ABS the brake system alerts the rider that the wheels...

Page 32: ... is principally executed when the vehicle is advanc ing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even vehicles equipped with ABS cannot be prevented from falling over if braked suddenly The ABS does not work when the main switch is turned to OFF The conventional braking function can be used Wheel lock A condition that occurs when the rotation o...

Page 33: ...n and above Multi function display WARNING EW3P61020 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on ...

Page 34: ...eling and traveling 5 km 3 mi Clock To set the clock 1 Push the SELECT button and RESET but ton together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Fuel meter The fuel...

Page 35: ...button to switch the display between the ambient temperature mode and the fuel consumption modes in the following order Air ambient temperature km L or L 100 km instantaneous fuel consumption AV_ _ km L or AV_ _ L 100 km average fuel consumption Air ambient temperature Ambient temperature mode This display shows the ambient temperature from 9 C to 50 C in 1 C increments The tem perature displayed ...

Page 36: ... displayed To reset the average fuel consumption display push the RESET button to select the mode again and then push the RESET button for 1 second while the display is flashing NOTE 1 To switch between the two average fuel con sumption displays push the RESET button for 1 second when either display is shown After resetting an average fuel consumption display _ _ will be shown for that display unt...

Page 37: ... button for 1 second while the display is flashing After resetting the average fuel consumption display _ _ will be shown for that display until the vehicle has traveled 1 km 0 6 mi CAUTION EC3P61041 If there is a malfunction will be dis played Replace the meter assembly Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circu...

Page 38: ...witch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal inter ference which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine re register the standard keys If the multi function display indicates any fault c...

Page 39: ... 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 40: ...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 41: ...al 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 42: ...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 Test coupler adapter 90890 03149 1 21 4 56 4 58 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 32 4 16 5 39 8 120 8 121 8 143 8 144 8 151 8 152 8 153 8 157 8 159 8 160 8 161 8 162 8 163 8 164 8 165 8 166 8 167 8...

Page 43: ... set 90890 03120 3 14 Oil pressure adapter B 90890 03124 3 14 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 26 4 77 Damper rod holder 90890 01447 YM 01447 4 69 4 70 Slide metal installer 90890 01508 4 71 Fork seal driver 90890 01502 YM A0948 4 71 4 72 Final gear backlash band 90890 01511 4 93 Tool name Tool No Illustration Reference pages ...

Page 44: ...iver attachment 90890 01186 Replacement 27 mm YM A9409 1 4 100 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 6 5 7 Pivot shaft wrench adapter 90890 01476 5 6 5 7 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 11 5 14 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 16 5 32 5 35 5 79 6 13 Valve spring compressor 90890 04019 YM 04019 5 22 5 27 Tool name...

Page 45: ... 5 23 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 23 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 23 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 31 5 32 5 35 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 31 Universal clutch holder 90890 04086 YM 91042 5 48 5 51 Tool name Tool No Illustration Reference pages ...

Page 46: ...ing retainer wrench 90890 04140 Middle drive shaft bearing retainer wrench YM 04140 5 68 Gear lash measurement tool 90890 01467 YM 01467 5 71 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 83 Piston ring compressor 90890 05158 YM 08037 5 88 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 99 Tool name Tool No Illustration Reference pages 0 40 0 30 0 35 0 25 0 20 0 ...

Page 47: ... adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 13 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 13 Pressure gauge 90890 03153 YU 03153 7 7 Tool name Tool No Illustration Reference pages YU 01083 3 YU 24460 01 YU 33984 ...

Page 48: ...dapter 90890 03176 YM 03176 7 7 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 8 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 162 Tool name Tool No Illustration Reference pages ...

Page 49: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 31 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING 2 45 ...

Page 50: ...B F 3P63 AUS Dimensions Overall length 2230 mm 87 8 in Overall width 750 mm 29 5 in Overall height 1450 mm 57 1 in Seat height 800 mm 31 5 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in Minimum turning radius 3100 mm 122 0 in Weight With oil and fuel 291 0 kg 642 lb Maximum load 212 kg 467 lb ...

Page 51: ...tity Total amount 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil pressure hot 30 0 kPa 1000 r min 4 4 psi 1000 r min 0 30 kgf cm 1000 r min Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Oil pump Oil pump type Trochoid...

Page 52: ...atio 75 48 25 28 1 395 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CR8E Manufacturer model DENSO U24ESR N Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 22 74 23 34 cm 1 39 1 42 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 45...

Page 53: ...A exhaust 25 90 26 10 mm 1 0197 1 0276 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Valve stem diameter exhaust 4 965 4 980 mm 0 1955 0 1960 in V...

Page 54: ...ing rate K1 intake 21 85 N mm 124 76 lb in 2 23 kgf mm Spring rate K2 intake 28 34 N mm 161 82 lb in 2 89 kgf mm Spring rate K1 exhaust 21 85 N mm 124 76 lb in 2 23 kgf mm Spring rate K2 exhaust 28 34 N mm 161 82 lb in 2 89 kgf mm Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 ...

Page 55: ...g type Barrel Dimensions B T 1 00 2 80 mm 0 04 0 11 in End gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0 04 0 11 in End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 0472 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit ...

Page 56: ... Balancer drive method Gear Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Clutch lever free play 1 9 20 7 mm 0 07 0 81 in Friction plate thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in Plate quantity 9 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring height 6 78 mm 0 27 in M...

Page 57: ...ection sensor Crankshaft position sensor resistance 421 569 Ω at 20 C 68 F Cylinder identification sensor output voltage ON More than 4 8 V Cylinder identification sensor output voltage OFF Less than 0 6 V Intake air pressure sensor output voltage 3 75 4 25 V Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F Idling condition Engine idling speed 1000 1100 r min Intake vacuum 33 3 kPa 9 ...

Page 58: ...n Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model METZELER Roadtec Z6G Manufacturer model BRIDGESTONE BT020F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model METZELER Roadtec Z6C Manufacturer model BRIDGESTONE BT020R 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 59: ...imit 4 5 mm 0 18 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 15 0 mm 0 59 in Caliper cylinder inside diameter 41 30 mm 1 63 in Recommended fluid DOT 4 Clutch Recommended fluid DOT 4 Master cylinder inside diameter 14 0 mm 0 5...

Page 60: ...n Spring free length 154 6 mm 6 09 in Installed length 136 2 mm 5 36 in Spring free length 73 9 mm 2 91 in Installed length 67 3 mm 2 65 in Soft Spring rate K1 91 00 N mm 519 60 lb in 9 28 kgf mm Spring rate K2 124 00 N mm 708 04 lb in 12 64 kgf mm Spring stroke K1 0 0 42 0 mm 0 00 1 65 in Spring stroke K2 42 0 60 0 mm 1 65 2 36 in Hard Spring rate K1 124 00 N mm 708 04 lb in 12 64 kgf mm Spring s...

Page 61: ...ap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer LNX07 DENSO Standard output 14 0 V 590 W 5000 r min Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Volt...

Page 62: ... Brush spring force 5 28 7 92 N 19 01 28 51 oz 538 808 gf Commutator diameter 24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer MS5F 631 JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 2 pcs Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω at 20 C 68 F Performance 108 116 dB 2 m 6 6 ft Turn signal hazar...

Page 63: ...er ACM33211 M05 MATSUSHITA Coil resistance 96 0 Ω Thermo unit Model manufacturer 25978 MITSUBISHI Resistance at 80 C 290 0 390 0 Ω Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Auxiliary DC jack fuse 3 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS motor fuse 30 0 A ABS control unit fuse 10 0 A Backup fuse 10...

Page 64: ...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 65: ... Nm 1 0 m kg 7 2 ft lb Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Camshaft sprocket bolt M7 4 24 Nm 2 4 m kg 17 ft lb Water pump assembly bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Water pump housing cover bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe 1 bolt M6 2 10 Nm 1 0 m ...

Page 66: ...t lb Generator cover bolt M6 11 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt M6 10 12 Nm 1 2 m kg 8 7 ft lb Middle gear case cover bolt M6 9 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 8 12 Nm 1 2 m kg 8 7 ft lb Rear balancer cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Oil baffle plate 1 bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil baffle plate 2 bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessi...

Page 67: ...um retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stator coil assembly bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position switch bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Crankshaft position sensor bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb O2 sensor M18 1 45 Nm 4 5 m kg 32 ft lb Intake air temperature sensor M12 1 18 Nm 1 8 m kg 13 ft lb Cylinder identificat...

Page 68: ...the connecting rod nuts to 20 Nm 2 0 m kg 14 ft lb and then tighten them further to reach the specified angle 115 125 NOTE Crankcase bolt Tighten the crankcase bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence loosen and retighten the bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence and then tighten them further to reach the specified angle 115 125 in the proper ...

Page 69: ...top M10 2 37 Nm 3 7 m kg 27 ft lb Pinch bolt front side M8 1 24 Nm 2 4 m kg 17 ft lb Pinch bolt rear side M8 2 24 Nm 2 4 m kg 17 ft lb Pivot shaft M28 1 23 Nm 2 3 m kg 17 ft lb Pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Pivot shaft locknut M28 1 115 Nm 11 5 m kg 85 ft lb Pivot shaft locknut retainer bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Relay arm and frame nut M10 1 40 Nm 4 0 m kg 29 ft lb Conne...

Page 70: ... ft lb Windshield upper inner bracket and windshield drive unit bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Windshield lower inner bracket and windshield drive unit bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Rearview mirror nut M6 4 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Windshield drive unit side rail bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Side cover bolt M6 3 7 Nm 0 7 m kg 5 1...

Page 71: ...ke caliper bleed screw M8 3 6 Nm 0 6 m kg 4 3 ft lb Front brake pad bolt M10 2 17 Nm 1 7 m kg 12 ft lb Rear brake caliper bolt M10 2 27 Nm 2 7 m kg 19 ft lb Rear brake hose rear wheel sen sor lead holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear brake caliper bleed screw M7 1 6 Nm 0 6 m kg 4 3 ft lb Hydraulic unit nut M8 3 16 Nm 1 6 m kg 11 ft lb Metering valve bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Propo...

Page 72: ...e does not protrude past the fork 4 In the order pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening Shift arm pinch bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod locknut M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive shaft dust cover bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Final gear oil drain bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final gear oil f...

Page 73: ...TIGHTENING TORQUES 2 24 1 2 3 4 ...

Page 74: ...and exhaust Water pump impeller shaft Oil pump rotors inner and outer and oil pump shaft Oil pump drive sprocket Oil strainer Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Push rods and ball Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bolt Damper drive ca...

Page 75: ...er head cover gasket Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 76: ...hrottle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Silicon grease Clutch lever pivot bolt and metal to metal moving parts Silicon grease Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing Oil...

Page 77: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 15 14 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 ...

Page 79: ...strainer 2 Oil pump 3 Relief valve assembly 4 Oil filter 5 Oil cooler 6 Main gallery 7 Front balancer shaft 8 Rear balancer shaft 9 Oil nozzle 10 Intake camshaft 11 Exhaust camshaft 12 Main axle 13 Oil pipe 14 Drive axle 15 Middle drive shaft assembly ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 3 2 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 6 5 4 3 2 1 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 2 3 4 5 6 7 8 9 ...

Page 87: ...CATION SYSTEM CHART AND DIAGRAMS 2 38 1 Rear balancer 2 Oil delivery pipe 2 3 Engine oil drain bolt 4 Oil level switch 5 Crankshaft 6 Front balancer 7 Crank pin 8 Oil delivery pipe 3 9 Relief valve assembly ...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 4 5 3 2 1 9 8 6 7 ...

Page 89: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil strainer 2 Oil delivery pipe 2 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil delivery pipe 3 8 Oil pan 9 Oil pump ...

Page 90: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20420 COOLING SYSTEM DIAGRAMS A C D B B D A 6 5 15 6 7 8 9 9 10 1 2 3 4 12 11 16 17 18 19 13 14 5 C ...

Page 91: ...r outlet hose 6 Radiator 7 Coolant reservoir breather hose 8 Thermostat inlet pipe 2 9 Coolant reservoir hose 10 Radiator inlet hose 11 Thermostat inlet hose 2 12 Thermostat assembly 13 Water jacket joint 14 Oil cooler 15 Oil cooler inlet hose 16 Water pump outlet pipe 17 Water pump breather hose 18 Radiator outlet hose 19 Water jacket joint inlet hose ...

Page 92: ...COOLING SYSTEM DIAGRAMS 2 43 A A 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12 ...

Page 93: ...1 2 Thermostat inlet hose 2 3 Radiator inlet hose 4 Radiator 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Water pump 11 Water jacket joint 12 Water pump breather hose ...

Page 94: ...CABLE ROUTING 2 45 EAS20430 CABLE ROUTING B B A A B B A B C D E F G G H H I J K L M 1 1 1 2 2 2 2 3 3 3 4 4 4 5 5 5 6 7 8 9 11 11 12 12 10 11 12 13 14 15 16 17 18 19 20 20 20 21 21 21 1 2 3 M ...

Page 95: ... switch lead to the inside of the clutch hose E Route the immobilizer unit lead to the inside of the clutch hose F Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torques making sure to tighten the brake hose joint bolt 1 last G To front cowling wire harness H Install the horn L s...

Page 96: ...47 B B C C D D A A E E A A B C D B C D A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 19 20 21 22 23 24 25 26 27 27 28 29 29 30 31 32 33 34 35 36 37 38 D F G M N P 27 29 29 18 O H ...

Page 97: ... lead to the battery box with a plastic locking tie Face the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Faste...

Page 98: ...CABLE ROUTING 2 49 A B C D E 1 1 2 3 4 5 6 7 8 9 11 10 12 ...

Page 99: ...raulic unit 10 Brake pipe metering valve to right front brake caliper 11 Rear brake light switch 12 Brake hose proportioning valve to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 10 20 mm 0 39 0 79 in D Route the rear brake light switch lead under the rear wheel sensor le...

Page 100: ...CABLE ROUTING 2 51 A B C 1 2 3 4 6 5 7 8 9 10 11 12 ...

Page 101: ...Fasten the handlebar switch leads to the front cowling wire harness with a plastic locking tie Face the end of the plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Fasten the front cowling wire harness to the radiator inlet hose with a plastic lockin...

Page 102: ...CABLE ROUTING 2 53 A A B C C B A A A B C D F E H I J K L M N O P Q R S T U V 1 2 6 6 8 14 14 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 G 6 7 3 5 4 ...

Page 103: ...ff from the wire harness to the guide on the holder with a plastic locking tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie G Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of t...

Page 104: ...CABLE ROUTING 2 55 A A B B C C B B A A A B C E D F G H I J K 2 2 1 1 4 4 4 5 5 5 6 7 8 9 10 11 12 13 3 3 3 14 15 16 17 16 17 18 19 20 21 22 ...

Page 105: ...tor lead to the outside of the rear shock absorber spring preload adjusting cable and under the hydraulic unit breather hose D Pass the stator coil lead rectifier regulator lead and hydraulic unit breather hose through the guide on the frame making sure to route the hose to the outside of the leads E Fasten the leads to ABS wire harness and rear brake light switch that branch off from the wire har...

Page 106: ...CABLE ROUTING 2 57 C B H A D E F G I I J K L M N O P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 31 ...

Page 107: ...ing tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupler holder so that the end w...

Page 108: ...CABLE ROUTING 2 59 D A B B C E 1 2 3 4 ...

Page 109: ...er on the rear fender making sure that the leads are not routed on top of the holder B Fasten the tail brake light assembly lead and license plate light lead with the holder C Route the tail brake light assembly lead and license plate light lead between the ribs on the rear fender D Route the intake air temperature sensor lead under the wire harness E Fasten the intake air temperature sensor lead ...

Page 110: ...CABLE ROUTING 2 61 A A A B C D E P F H I J K L M N Q R 1 2 3 4 5 6 9 10 11 13 14 15 16 G 7 8 O 12 ...

Page 111: ... with the band after the headlight lead branches off from the harness J Secure the front cowling wire harness at the location shown in the illustration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay K Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking tie makin...

Page 112: ...CABLE ROUTING 2 63 C C A B A B C C A B J C D F G G I 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 E H 11 ...

Page 113: ...lator lead 16 Rectifier regulator 17 ABS motor coupler A Install the ABS motor relay completely onto the tab on the hydraulic unit bracket B Install the hydraulic unit solenoid coupler completely onto the tab on the hydraulic unit bracket C 87 93 D 5 7 mm 0 20 0 28 in E Install the hydraulic unit breather hose so that the white paint mark on the hose is facing down F Make sure that the brake hose ...

Page 114: ...CABLE ROUTING 2 65 ...

Page 115: ...HECKING THE IGNITION TIMING 3 10 MEASURING THE COMPRESSION PRESSURE 3 11 CHECKING THE ENGINE OIL LEVEL 3 12 CHANGING THE ENGINE OIL 3 13 MEASURING THE ENGINE OIL PRESSURE 3 14 ADJUSTING THE CLUTCH LEVER 3 15 CHECKING THE CLUTCH FLUID LEVEL 3 15 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3 15 CLEANING THE AIR FILTER ELEMENT 3 16 CHECKING THE THROTTLE BODY JOINTS 3 16 CHECKING THE FUEL LINE 3 17 CHECKING ...

Page 116: ...STEERING HEAD 3 26 ADJUSTING THE HANDLEBAR POSITION 3 27 CHECKING THE FRONT FORK 3 28 ADJUSTING THE FRONT FORK LEGS 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 29 ADJUSTING THE SIDE PANELS 3 30 ADJUSTING THE RIDER SEAT HEIGHT 3 31 CHECKING THE TIRES 3 32 CHECKING THE WHEELS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDALS 3 34 LUBRICATING THE S...

Page 117: ......

Page 118: ...el hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Clean 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 an...

Page 119: ... operation Lubricate with lithium soap based grease 20 Fuel injection Adjust engine idling speed and synchronization 21 Engine oil Change Check oil level and vehicle for oil leakage 22 Engine oil filter car tridge Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 Front and rear ...

Page 120: ...er to THERMOSTAT on page 6 6 2 Disconnect Throttle cables 3 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 9 4 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor with...

Page 121: ... crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the...

Page 122: ...page 5 9 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install All removed parts NOTE F...

Page 123: ...le bodies 1 2 and 4 using the air screw 1 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 was removed turn the screw 3 4 turn in and be sure to synchronize the throt tle body CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation NOTE The difference in ...

Page 124: ... meter disappear except the odometer tripmeter fuel reserve tripmeter dis plays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 3 Press the SELECT button to select the CO adjustment mode Co 1 or the diagnostic mode dIAG 4 After selecting CO simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the selection 5 Press the SELECT and RESET buttons to sel...

Page 125: ...NERAL CHASSIS on page 4 1 3 Install Digital tachometer onto the spark plug lead of cylinder 1 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Check Engine idling speed Out of specification Adjust 6 Adjust Engine idling speed a Turn the engine idle speed adjustment screw 1 in direction a or b until the specified en gine idling speed is obtained 7 Adjust Throttle cable free play Refer to ADJUST...

Page 126: ...ion 4 Install T bar Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Spark pl...

Page 127: ... sure all connections are tight and free of corrosion 1 Stand the vehicle on a level surface NOTE Place the vehicle on the centerstand 2 Remove Right side cowling Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 3 Remove Timing mark accessing plug 1 along with the copper washer 4 Connect Timing light 1 onto the spar...

Page 128: ... on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 4 Disconnect the all spark plug caps 5 Remove Spark plug CAUTION ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 6 Install Compression gauge 1 7 Measure Compression pressure Out of spec...

Page 129: ...um level mark b Below the minimum level mark Add the recommended engine oil to the proper level CAUTION EC3P61036 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERVING II b Do not allow foreign materials to ente...

Page 130: ...ew oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVE...

Page 131: ...have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Right side cowling Refer to GENERAL CHASSIS on page 4 1 4 Remove Main gallery bolt WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge set 1 Oil pressure adapter B 2 6 Measure Engine oil pressure...

Page 132: ...cantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed ...

Page 133: ...Refer to GENERAL CHASSIS on page 4 1 2 Clean Air filter element Apply compressed air to the outer surface of the air filter element 3 Check Air filter element Damage Replace CAUTION EC3P61043 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also a...

Page 134: ...SSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly C...

Page 135: ...instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 4 Start the engine warm it up for several min utes and then turn it off 5 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles 6 Install Left side panel Refer to GENERAL...

Page 136: ... gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counte...

Page 137: ...ant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for ...

Page 138: ...o brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position che...

Page 139: ...m 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 parts Therefore always clean up any spilt brake fluid immedi...

Page 140: ...AKE on page 4 25 REAR BRAKE on page 4 37 and ABS AN TI LOCK BRAKE SYSTEM on page 4 50 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking ef fect starts If the switch is not properly adjusted ABS mal function code No 23 may be...

Page 141: ...ENERAL CHASSIS on page 4 1 2 Bleed ABS a Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Full...

Page 142: ...ver bolt 2 as shown in the illus tration when viewed directly from the side Incorrect Adjust 2 Adjust Shift pedal position a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position NOTE Check that the groove c in the shift pedal is be tween the projections d on the frame c Tighten both locknuts to specification EAS21460 CHECKING THE FINAL GEAR O...

Page 143: ...vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 75 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 a...

Page 144: ...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 page 4 75 ET3P61034 ADJUSTING THE HANDLEBAR POSITION 1 Check Handlebar position NOTE The handlebar position can be adjusted to one of three positions to suit the rider s preference 2 Adjust Handlebar position a Remove the plates 1 b Remov...

Page 145: ...age 4 65 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13150 Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION ECA13570 Grooves are provided to indicate the ad justment po...

Page 146: ...f it falling over Spring preload CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 2 Current setting Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Standard 12 click s out Maximum 1 click s out With the adjusting knob fully turned in ...

Page 147: ...ilation to suit the riding conditions To open a side panel a Remove the quick fastener screws 1 b Pull the side panel to the open position and then install the quick fastener screws 1 Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping i...

Page 148: ... the rider s preference The rider seat height was adjusted to the lower position at delivery 2 Remove Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 3 Remove Rider seat height position adjuster 1 NOTE Remove the rider seat height position adjuster by pulling it upward 4 Adjust Rider seat height To change to the high position a Move the rider seat holder cover 1 to the lower positio...

Page 149: ... the rider seat height position adjuster 2 so that the L mark a is aligned with the match mark b c Insert the projection c on the front of the rid er seat into seat holder for low position 3 as shown d Align the low position projection d on the bottom of the rider seat with the L position slot e and then push the rear of the seat down to lock it in place as shown 5 Install Passenger seat Refer to ...

Page 150: ...om sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re plac...

Page 151: ...r re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricat...

Page 152: ...voting point and metal to metal moving parts of the centerstand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease ...

Page 153: ...t bulb Secure the new headlight bulb with 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 7 Attach Headligh...

Page 154: ...TEM 3 37 Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 1 b a b a ...

Page 155: ...ISASSEMBLING THE REAR WHEEL 4 22 CHECKING THE REAR WHEEL 4 22 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 22 ASSEMBLING THE REAR WHEEL 4 22 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 23 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 23 FRONT BRAKE 4 25 INTRODUCTION 4 30 CHECKING THE FRONT BRAKE DISCS 4 30 REPLACING THE FRONT BRAKE PADS 4 31 REMOVING THE FRONT BRAKE CALIPERS 4 32 DISASSEMBL...

Page 156: ...ING VALVE 4 55 INSTALLING THE HYDRAULIC UNIT 4 55 HYDRAULIC UNIT OPERATION TESTS 4 56 TRIAL RUN 4 59 HANDLEBARS 4 60 REMOVING THE HANDLEBARS 4 62 CHECKING THE HANDLEBARS 4 62 INSTALLING THE HANDLEBARS 4 62 FRONT FORK 4 65 REMOVING THE FRONT FORK LEGS 4 68 DISASSEMBLING THE FRONT FORK LEGS 4 68 CHECKING THE FRONT FORK LEGS 4 69 ASSEMBLING THE FRONT FORK LEGS 4 70 INSTALLING THE FRONT FORK LEGS 4 73...

Page 157: ...4 92 MEASURING THE FINAL GEAR BACKLASH 4 92 ADJUSTING THE FINAL GEAR BACKLASH 4 93 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 94 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 94 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 95 REMOVING AND INSTALLING THE BEARINGS 4 96 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 96 CHECKING THE DRIVE SHAFT 4 99 INSTALLING THE DRIVE SHAFT AND FINA...

Page 158: ...at 1 3 Grab bar 1 4 Left rear cowling 1 5 Right rear cowling 1 6 Center rear cowling 1 7 Left side cover 1 8 Right side cover 1 9 Rider seat height position adjuster 1 For installation reverse the removal proce dure 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 21 Nm 2 1 m kg 15 ft Ib 3 1 4 7 2 5 9 6 8 ...

Page 159: ...coupler 1 Disconnect 7 Bottom cowling 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 Disconnect 13 Front cowling left inner panel 1 1 14 Front cowling left inner panel 2 1 15 Plastic band 2 Disconnect 16 Plastic holder 1 Disconnect T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 ...

Page 160: ...9 Horn connector 4 Disconnect 20 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT 10 9 4 8 20 1 3 6 7 2 12 11 5 12 16 11 14 13 9 18 19 17 19 15 18 18 ...

Page 161: ...wer inner bracket 1 5 Rearview mirror 2 6 Accessory box solenoid coupler 1 Disconnect 7 Auxiliary DC jack coupler 1 Disconnect 8 Accessory box 1 9 Accessory box solenoid 1 10 Headlight coupler 2 Disconnect 11 Auxiliary light coupler 2 Disconnect 12 Front cowling 1 For assembly reverse the disassembly pro cedure 7 7 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 I...

Page 162: ...IS 4 5 Removing the headlight assembly Order Job Parts to remove Q ty Remarks Front cowling Refer to Disassembling the front cowling assembly 1 Headlight assembly 1 For installation reverse the removal proce dure 1 ...

Page 163: ...bly coupler 1 Disconnect 5 Meter assembly 1 6 Relay unit coupler 1 Disconnect 7 Relay unit 1 8 Turn signal hazard relay coupler 1 Disconnect 9 Turn signal hazard relay 1 10 Headlight relay dimmer coupler 1 Disconnect 11 Headlight relay dimmer 1 12 Lean angle sensor coupler 1 Disconnect 13 Lean angle sensor 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0...

Page 164: ...ebar completely to the left c Install the adjusting knob shaft 1 onto the left headlight beam adjusting cable 2 d Place front cowling left inner panel 2 3 be tween the front cowling assembly and the steering stem e Fit the top and side of inner panel 2 into the front cowling assembly to the left of the meter assembly f Fit inner panel 2 under the right side of the ac cessory box NOTE Pull the fron...

Page 165: ...in front cowling right inner panel 2 3 making sure to align the projection a on the shaft s sleeve with the slot b in the panel and then install the nut d Install the headlight beam adjusting knob 4 e Fit the lower right corner of inner panel 2 into the front cowling assembly making sure to align the bolt hole in the panel with the bolt hole in the cowling f Fit the top and side of inner panel 2 i...

Page 166: ...GENERAL CHASSIS 4 9 b a 1 2 ...

Page 167: ...arts to remove Q ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 For installation reverse the removal proce dure 1 2 T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib ...

Page 168: ...orage compartment 1 8 ECU engine control unit 1 9 Rear lower fuel tank bracket 1 10 Intake air temperature sensor 1 11 Bypass air unit inlet hose 1 Disconnect 12 Crankcase breather hose 1 Disconnect 13 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 14 Air filter case joint clamp screw 4 Loosen 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 18 Nm 1...

Page 169: ...18 Filter assembly 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks 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 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib 5 6 7 1 2 4 11 4 4 8 9 10 14 16 3 4 14 17 18 15 12 17 13 11 14 ...

Page 170: ...ont brake caliper 2 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 11 Front brake disc 2 For installation reverse the removal proce dure T R 18 Nm 1 8 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft I...

Page 171: ...FRONT WHEEL 4 14 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 pro cedure ...

Page 172: ...BLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver 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 Wheel axle Roll the wheel axle on a flat surface B...

Page 173: ...nsor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Measure Front wheel sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the front wheel sensor coupler terminals as shown b Measure the front wheel sensor resistance 3 Check Front wheel sensor rotor 1 Cracks damage Replace the front wheel assembly NOTE The wheel sensor rotor of the vehicle is inserted un...

Page 174: ...iscs 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 X2 mark at the bottom of the wheel f Repeat steps...

Page 175: ...ck Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 3 Lubricate Oil seal lips 4 Install Collar Front wheel sensor housing Front wheel NOTE Align the slot in the front wheel sensor housing with the projection of the front fork before as sembly 5 Install Front wheel axle Front wheel axle bolt Front wheel axle pinch bolts CAUTION EC3P61022 Before tightening the wheel axle bolt p...

Page 176: ...der pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 6 Install Front brake calipers Front wheel sensor NOTE When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION EC3P61023 Make sure there are no foreign materials in the wheel hub Foreign material...

Page 177: ...nsor 1 3 Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut 1 5 Brake torque rod 1 6 Rear wheel axle 1 7 Rear brake caliper 1 8 Rear wheel 1 9 Rear wheel sensor housing 1 10 Collar 1 11 Rear brake disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 4 3 5 7 9 11 6 T R 18 Nm ...

Page 178: ... remove Q ty Remarks 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Spacer 1 10 Spacer 1 11 Oil seal 1 12 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 179: ... CHECKING THE FRONT WHEEL on page 4 15 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 15 EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR CAUTION EC3P61032 Handle the ABS components with care since they have been acc...

Page 180: ...R BRAKE DISC on page 4 43 3 Lubricate Oil seal lips 4 Install Rear wheel sensor housing Rear wheel Rear brake caliper Rear wheel axle Brake torque rod Rear wheel axle nut NOTE Align the slot a of the rear wheel sensor hous ing 1 with the projection b of the rear brake caliper bracket 2 and then assemble them After assembling the rear wheel sensor hous ing and the rear brake caliper bracket make su...

Page 181: ...hen installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 7 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly T R Brake torque rod nut 30 Nm 3 0 m kg 22 ft lb Rear wheel axle nut 125 Nm 12 5 m kg 90 ft lb Rear wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Rear wheel sensor bolt 30 N...

Page 182: ...of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LS LS LS LS T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 2 5 4 4 5 3 3 ...

Page 183: ...ir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Brake hose front brake master cylinder to hy draulic unit 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation ...

Page 184: ...mbling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 185: ...der 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Brake hose hydraulic unit to front brake cali pers 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 f...

Page 186: ...ke calipers 1 Brake pad bolt 2 2 Brake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston seal 8 6 Bleed screw 1 7 Bleed screw 1 Right side only For assembly reverse the disassembly pro cedure T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New LS 1 2 2 3 4 4 1 6 3 7 5 5 5 5 ...

Page 187: ...re applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 13 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 ...

Page 188: ...liper 1 Measure Brake pad wear limit 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 new 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 w...

Page 189: ...e caliper drain the brake fluid from the entire brake system 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose hydraulic unit to front brake cali pers 3 Brake hose metering valve to right front brake caliper 4 NOTE Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following proced...

Page 190: ...ternal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front bra...

Page 191: ...ormance When refilling be careful that water does not enter the brake master cylinder reser voir and 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 parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDR...

Page 192: ... master cylinder reservoir diaphragm Damage wear Replace 4 Check Brake hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT 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 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Bra...

Page 193: ...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 master cylinder reser voir and 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 pain...

Page 194: ...BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad shim 2 4 Rear brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure ...

Page 195: ...id reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Right footrest assembly 1 8 Rear brake light switch 1 9 Brake hose union bolt 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib...

Page 196: ...tion reverse the removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib New New T R 28 Nm 2 8 m kg 20 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib ...

Page 197: ...mbling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 198: ... SYSTEM ABS on page 3 23 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose proportioning valve to rear brake caliper 1 4 Rear brake caliper bolt 2 Loosen 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle nut 1 7 Brake torque rod 1 8 Rear wheel axle 1 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 199: ...Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 200: ...k 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 30 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 30 5 Adjust Brake disc de...

Page 201: ...el 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 22 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 23 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire...

Page 202: ...ivery passage 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 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 fluid Nev...

Page 203: ...ers Brake hose proportioning valve to rear brake caliper 1 Brake hose union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 CAUTION EC3P61044 When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cali per 4 Remove Rear brake caliper bolts Rear brake ...

Page 204: ...ngy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 23 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Brake hose rear brake master cylinder to hy draulic unit 3 NOTE To collect any remaining brake flui...

Page 205: ...rake 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 Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage pai...

Page 206: ...REAR BRAKE 4 49 7 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 21 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 ...

Page 207: ... unit HU 5 Rear wheel sensor rotor 6 Rear wheel sensor 7 Rear brake caliper 8 Brake hose proportioning valve to rear brake caliper 9 Left front brake caliper 10 Right front brake caliper partially operated together with the rear brake 11 Front wheel sensor 12 Front wheel sensor rotor 13 Brake hose rear brake master cylinder to hydraulic unit 14 Proportioning valve 15 Brake hose hydraulic unit to p...

Page 208: ...d Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 23 Brake fluid reservoir Refer to REAR BRAKE on page 4 37 1 Tail brake light assembly coupler 1 Disconnect 2 License plate light connector 2 Disconnect 3 Tail brake light assembly 1 4 Seat lock cable assembly 1 5 Rear fender assembly 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 209: ...n bolt Copper washer 1 2 8 Brake hose hydraulic unit to proportioning valve 1 9 Brake hose union bolt Copper washer 2 4 10 Brake hose hydraulic unit to metering valve 1 11 Hydraulic unit 1 12 Hydraulic unit solenoid coupler 1 Disconnect 13 ABS motor coupler 1 Disconnect 14 Brake hose union bolt Copper washer 1 2 15 T R 19 Nm 1 9 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib...

Page 210: ... the removal proce dure Removing the hydraulic unit Order Job Parts to remove Q ty Remarks 15 T R 19 Nm 1 9 m kg 13 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 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 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 16 Nm 1 6 m kg 11 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 17 18 13 16 11 10 9 8 9 9 1 2 1 3 6 3 5 5 4 7 7 9 14 1...

Page 211: ...iately Do not allow any brake fluid to contact the couplers Brake fluid may damage the cou plers and cause bad contacts If the union bolts for the hydraulic unit have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake hose 1 front brake master cylinder to hydraulic unit Brake hose 2 rear brake master cylinder to hydraulic unit Brake hose 3 hydrau...

Page 212: ...lve 1 to the metering valve Brake hose union bolt NOTE The brake hose 1 contacts the stopper a on the metering valve 4 Install Copper washers Brake hose 1 hydraulic unit to metering valve Brake hose 2 hydraulic unit to proportion ing valve Brake hose 3 hydraulic unit to front brake calipers Brake hose 4 rear brake master cylinder to hydraulic unit Brake hose 5 front brake master cylinder to hydrau...

Page 213: ...orm a trial run Refer to TRIAL RUN on page 4 59 EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Hydraulic unit operation test 1 this test checks the function of the ABS after the syste...

Page 214: ...nd per son should confirm that the rear brake force is released during the second pulse in the brake pedal third pulse overall by manually applying force to rotate the rear wheel If the rear brake force is released during the second pulse in the brake pedal the second person will be able to rotate the rear wheel for 0 1 second CAUTION EC3P61013 Check that the pulse is felt in the brake le ver once...

Page 215: ...page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery NOTE If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic unit operation test 2 If the battery voltage is lower than 10 V the ABS warning light comes on and the ABS does not operate 5 Connect the test coupler adapter 1 to the ABS test coupler 2 6 Set the engine stop switch 1 to 7 T...

Page 216: ...ing action has stopped 12 After the pulsating action has stopped in the brake pedal it is generated in the brake lever 0 5 second later and continues for approxi mately 2 seconds NOTE The reaction force pulsating action consists of two series of quick pulses CAUTION EC3P61018 Check that the pulsating action is felt in the brake lever brake pedal and again in the brake lever in this order If the pu...

Page 217: ...Parts to remove Q ty Remarks 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 3 Clutch master cylinder assembly 1 4 Left handlebar 1 5 Lead holder 1 6 Left handlebar switch 1 7 Grip end 1 8 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 218: ...itch connector 2 Disconnect 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Lead holder 1 10 Right handlebar switch 1 For installation reverse the removal proce dure ...

Page 219: ...ace WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully d...

Page 220: ...be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder assembly Front brake master cylinder holder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the mating surfaces of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt then the lower bolt 10 Ins...

Page 221: ...tch master cylinder holder with the punch mark a on the left handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 T R Clutch 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 ...

Page 222: ...Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 13 1 Battery holder 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Upper bracket pinch bolt 1 Loosen 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 For installation reverse the removal proce dure ...

Page 223: ...ocedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Nut 1 4 Damper adjusting rod 1 5 Spacer 1 6 Washer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Spring 1 16 Oil flow stopper 1 ...

Page 224: ... 1 1 D 52 mm 2 05 in l 12 mm 0 47 in 19 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 20 Inner tube bushing 1 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks ...

Page 225: ...NING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Hold the nut 1 and loosen the cap bolt 2 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver...

Page 226: ... assembly bolt 6 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful ly CAUTION EC3P61027 Excessive force will damage the bushings Damaged bushings must be replaced Avoid bottoming the inner tube into the out er tube during the abov...

Page 227: ...ss of stability NOTE When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing 1 Outer tube bushing 2 Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Inner tube bushing 1 Oil flow stopper 2 Spring Damper rod assembly 3 CAUTION EC3P61028 Allow the damper rod assembly to slide slowly dow...

Page 228: ...NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove Slide metal installer 9...

Page 229: ...mbly slowly because the fork oil may spurt out 11 Slowly stroke the inner tube 1 up and down 12 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 13 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork sp...

Page 230: ... tube NOTE Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Ma...

Page 231: ...FRONT FORK 4 74 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 28 ...

Page 232: ...Immobilizer unit coupler cover holder 1 2 Immobilizer unit coupler cover 2 3 Immobilizer unit coupler 1 Disconnect 4 Main switch coupler 2 Disconnect 5 Lower bracket cover 1 6 Brake hose joint bracket bolt 2 7 Steering stem nut 1 8 Upper bracket 1 9 Handlebar bracket 1 10 Lock washer 1 11 Upper ring nut 1 T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS ...

Page 233: ...wer bearing inner race 1 21 Upper bearing outer race 1 22 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 14 7 8 19 20 18 6 5 9 22 21 3 1 2 2 17 16 15 13 12 11 10 4 4 LS LT LT ...

Page 234: ...g races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer 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 Check Upper bracket Lower br...

Page 235: ...3 26 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 65 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 115 Nm 11 5 m kg 85 ft lb ...

Page 236: ...ect 3 Rear shock absorber spring preload adjusting lever nut 3 4 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 5 Connecting arm nut Washer Bolt 2 2 2 6 Connecting arm 2 7 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 8 Rear shock absorber assembly 1 9 Centerstand 1 10 Relay arm nut Bolt Spacer 1 1 1 New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R ...

Page 237: ...l proce dure Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 5 T R 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 7 7 10 3 10 1 2 LS LS 8 13 15 12 17 15 15 15 5 6 1616 1514 17 11 5 5 6 15 4 4 9 LS T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 238: ... the rear shock absorber at a point 15 20 mm 0 59 0 79 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 ...

Page 239: ... 3 Check Spacers Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Spacer Bearings 2 Install Bearing 1 2 to the relay arm 3 Install Relay arm NOTE Make sure that the embossed mark 5JW on the relay arm faces to the left EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly NOTE Make sure that the warning label on the rear shock absorber ass...

Page 240: ... on page 4 87 1 Right footrest bracket bolt 2 2 Pivot shaft end cover 1 3 Pivot shaft locknut retainer 1 4 Pivot shaft nut 1 5 Pivot shaft locknut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 9 Oil seal 2 10 Bearing 2 11 Collar 1 12 Oil seal 1 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 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 ...

Page 241: ...al proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 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 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17 16 15 12 11 10 8 9 18 14 13 9 10 7 ...

Page 242: ...s not smooth or if there is binding check the spacers bear ings washers and dust covers 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 Spacers Washer Bearings Collar 4 Check Spacers Washer Collar Oil seals Damage w...

Page 243: ...shaft locknut Pivot shaft nut 3 Swingarm 4 Connecting arm A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kg 17 ft lb T R Pivot shaft locknut 115 Nm 11 5 m kg 85 ft lb T R Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb 1 3 a A 3 2 b 2 A B b 4 4 ...

Page 244: ... the final drive assembly Order Job Parts to remove Q ty Remarks Final gear oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Rear wheel Refer to REAR WHEEL on page 4 20 1 Final drive assembly 1 For installation reverse the removal proce dure ...

Page 245: ...Job Parts to remove Q ty Remarks 1 Shift arm 1 2 Left footrest assembly 1 3 Sidestand switch coupler 1 Disconnect 4 Sidestand 1 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 For installation reverse the removal proce dure ...

Page 246: ...l seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing 1 6 Dust cover 1 7 Oil seal 1 8 Stopper bolt 1 Left hand threads 9 Stopper bolt shim s 10 Ring gear shim s 11 Ring gear 1 12 Bearing 1 13 Thrust washer 1 14 Coupling gear nut 1 15 Coupling gear 1 16 Bearing retainer 1 Left hand threads 17 Oil seal 1 ...

Page 247: ...n gear 1 19 Bearing 1 20 Final drive pinion gear shim s 21 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 For assembly reverse the disassembly pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks ...

Page 248: ...roken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider Troubleshooting chart When causes A or B shown in the table at the beginning of the TROUBLESHOOTING section ex ist check the following points YES NO Symptom Possible cause 1 A prono...

Page 249: ...n a new or fairly new vehicle may result from the applica tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to originate from EAS23580 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive assembly in a vise 2 Remove Final gear oil drain bolt 3 Drain Final gear oil from the final drive assembly 4 Measure Fin...

Page 250: ...nion gear 90 h Reinstall the bolt final gear backlash band and dial gauge i Repeat steps d to h three more times for a total of four measurements j If any of the readings are over specification adjust the final gear backlash EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 NOTE Working in a crisscross pattern loosen each bolt an...

Page 251: ...tion Adjust 3 Install Ring gear bearing housing along with the ring gear EAS23610 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove Ring gear 1 Stopper bolt 2 Stopper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper bolt shim s 3 Install Ring gear bearing housing 1 Stopper bolt shim s 2 Stopper bolt 3 Ring gear 4 CAUTION ECA14320 The stopper bolt has left hand threads To tighten...

Page 252: ...ling gear 1 with the coupling gear middle shaft tool 2 3 Remove Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14330 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove Final drive pinion gear WARNING EWA13800 Always use new bearings CAUTION ECA14340 The final drive pinion gear should only be re moved if ring gear replacement is nec...

Page 253: ...aring outer races with a socket or appropriate tool that matches the diameter of the races c Install the inner race onto the final drive pin ion gear 5 Install Collar 1 Oil seal 2 Bearing 3 with an appropriate press tool 4 and press NOTE The bearing can be reused but Yamaha recom mends installing a new one EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE Aligning the final drive pi...

Page 254: ... shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Where c a numeral on the final gear case to be di vided by 100 and added to 45 d a numeral usually on the outside of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positive...

Page 255: ...culated Final drive pinion gear Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14350 The bearing retainer has left hand threads To tighten the bearing retainer turn it coun terclockwise 3 Install Coupling gear 1 Coupling gear nut with the coupling gear middle shaft tool 2 Ring gear bearing thickness 13 00 mm 0 51 in B 45 51 100 3 35 100 35 40 5 100 13 45 0 51 3 0 35 35 40 0 05 13 4...

Page 256: ...ce with Plastigauge d Remove the ring gear bearing housing e Measure the width of the flattened Plasti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bear ing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from ...

Page 257: ... bolt M10 3 temporarily and then tighten them to the specified torques in the proper tightening sequence as shown 8 Install Shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm 9 Install Rear wheel Refer to REAR WHEEL on page 4 20 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 25 11 Check Shift pedal position Refer to ADJUSTING THE...

Page 258: ...SHAFT DRIVE 4 101 ...

Page 259: ...INDER HEAD 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 22 CHECKING THE VALVES AND VALVE GUIDES 5 22 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 25 CHECKING THE VALVE LIFTERS 5 26 INSTALLING THE VALVES 5 26 GENERATOR AND STARTER CLUTCH 5 28 REMOVING THE GENERATOR 5 31 REMOVING THE STARTER CLUTCH 5 31 CHECKING THE STARTER CLUTCH 5 31 INSTALLING THE STARTER CLUTCH 5 32 INS...

Page 260: ...6 CHECKING THE SHIFT SHAFT 5 57 CHECKING THE STOPPER LEVER 5 57 INSTALLING THE SHIFT SHAFT 5 57 OIL PUMP 5 58 CHECKING THE OIL PUMP 5 61 CHECKING THE RELIEF VALVE 5 61 CHECKING THE OIL DELIVERY PIPES 5 61 CHECKING THE OIL STRAINER 5 62 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PAN 5 62 MIDDLE GEAR 5 63 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 67 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBL...

Page 261: ... THE PISTON PIN 5 85 CHECKING THE CONNECTING RODS 5 86 INSTALLING THE CONNECTING RODS AND PISTONS 5 87 CRANKSHAFT 5 90 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 91 CHECKING THE OIL NOZZLES 5 91 CHECKING THE CRANKSHAFT 5 91 INSTALLING THE CRANKSHAFT 5 92 TRANSMISSION 5 94 REMOVING THE TRANSMISSION 5 99 CHECKING THE SHIFT FORKS 5 99 CHECKING THE SHIFT DRUM ASSEMBLY 5 99 CHECKING THE TRANSMISSION 5 ...

Page 262: ...nt Drain Refer to CHANGING THE COOLANT on page 3 19 Radiator Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Left muffler 1 4 Right muffler 1 5 Exhaust pipe assembly 1 6 Gasket 4 For installation reverse the removal proce dure T R 20 Nm 2 0 m kg 14 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 17 Nm 1 7 m kg 12 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 5...

Page 263: ...7 9 Thermostat Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 37 Left footrest assembly Sidestand Refer to SHAFT DRIVE on page 4 87 1 Clutch release cylinder 1 2 Dowel pi...

Page 264: ...nsor coupler 1 Disconnect 7 Gear position switch coupler 1 Disconnect 8 Ground lead 1 Disconnect 9 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 9 2 2 1 3 5 6 7 4 8 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 265: ... 1 11 Spacer 2 12 Engine mounting bolt right front upper side 1 13 Engine mounting bolt left front lower side 1 14 Engine mounting bolt left front upper side 1 15 Engine mounting nut rear upper side 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R...

Page 266: ...e Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E E 9 9 15 11 1 11 12...

Page 267: ...ght front lower side 9 Pinch bolts front side 10 Pinch bolts rear side 11 Engine brackets top 12 Engine bracket bolts top 13 NOTE Lubricate the engine mounting bolt rear lower side threads with engine oil Do not fully tighten the bolts 3 Tighten Engine mounting bolt left front upper side 5 4 Tighten Engine mounting bolt rear lower side 4 5 Tighten Spacer bolt 1 NOTE Tighten the spacer bolt 1 to sp...

Page 268: ...ed the bolts 15 and 13 should be flat against the engine and frame surface 12 Tighten Engine mounting bolts top 15 Engine bracket bolts top 13 13 Install Engine bracket left rear side 1 Engine bracket bolt left rear side 2 Engine mounting bolts left rear side 3 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 Pivot shaft wrench adapter 90890 01476 T R Engine mounting nut rear upper sid...

Page 269: ...ts left rear side 3 16 Install Brake pedal 1 NOTE Align the punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Engine bracket bolt left rear side 32 Nm 3 2 m kg 23 ft lb T R Engine mounting bolt left rear side 16 Nm 1 6 m kg 11 ft lb T R Brake pedal pinch bolt 8 Nm 0 8 m kg 5 8 ft lb 3 2 1 a b 1 ...

Page 270: ...Air cut off valve Reed valves Refer to AIR INDUCTION SYSTEM on page 7 9 1 Spark plug 4 2 Cylinder identification sensor 1 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing chain guide upper side 1 For installation reverse the removal proce dure 1 New New 4 5 5 5 2 8 LT LS 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib ...

Page 271: ...CKUP ROTOR on page 5 34 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Timing chain guide exhaust side 1 10 Pin 1 11 Timing chain guide intake side 1 For installation reverse the removal proce dure ...

Page 272: ... 1 NOTE Make sure that the tensioner rod has been fully set clockwise 4 Remove Timing chain tensioner Timing chain tensioner gasket 5 Remove Camshaft caps Dowel pins CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To ...

Page 273: ...haft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dimensions Intake A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 050 mm 1 2618 in Intake B 24 997 25 097 mm 0 9841 0 9881 in Limit 23 997 mm 0 9448 in Exhaust A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 9...

Page 274: ...heck Timing chain guide exhaust side Timing chain guide intake side Timing chain guide upper side Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner rod w...

Page 275: ...aft 2 Intake camshaft 3 with the camshaft sprockets CAUTION ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing a Install the timing chain onto both camshaft sprockets and then install the camshafts NOTE Make sure the holes a on each camshaft fac es up When installing the timing chain start with the exhaust camshaft and be sure to keep the ti...

Page 276: ...nner caps out 5 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating surface b 6 Install Timing chain tensioner Timing chain tensioner gasket a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful l...

Page 277: ...ation steps above 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 10 Install Cylinder head cover gasket Cylinder head cover NOTE Apply Three Bond 1514 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head...

Page 278: ...CAMSHAFTS 5 17 ...

Page 279: ...MOVAL on page 5 1 Camshafts Refer to CAMSHAFTS on page 5 9 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 25 Nm 2 5 m kg 18 ft lb Final Specified angle 175 185 New New 3 3 2 New 1 10 E ...

Page 280: ...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 figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times EAS24240 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 2 Tighten Cylind...

Page 281: ...ew one and perform the procedure again CAUTION EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bolt note that the angle from one corner to another is 60 f Tighten the cylinder head bolts M6 in proper tightening sequence as shown T R Cylinder head bolt M10 2nd 25 Nm 2 5 m kg 18 ft lb T R Cylinder...

Page 282: ...inder head Refer to CYLINDER HEAD on page 5 18 1 Valve lifter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 283: ... 24 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring...

Page 284: ...valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 020 0...

Page 285: ...d valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification 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 imp...

Page 286: ...e back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to...

Page 287: ...valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Lubricate Valve stem end with the recommended lubricant Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed length ...

Page 288: ...achment 2 6 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 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stal...

Page 289: ...k Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 1 Stator coil coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 7 Generator rotor 1 8 Woodruff key 1 9 Starter clutch gear 1 ...

Page 290: ...GENERATOR AND STARTER CLUTCH 5 29 10 Starter clutch 1 For installation reverse the removal proce dure Removing the generator rotor and starter clutch Order Job Parts to remove Q ty Remarks ...

Page 291: ...OR AND STARTER CLUTCH 5 30 Removing the stator coil assembly Order Job Parts to remove Q ty Remarks 1 Stator coil assembly lead holder 1 2 Stator coil assembly 1 For installation reverse the removal proce dure ...

Page 292: ...TARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear onto the starter clutch and hold the starter clutch b Whe...

Page 293: ... way of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt 3 Apply Sealant onto the stator coil assembly lead grommet 4 Install Generator cover gasket Generator cover T R Starter clutch bolt 32 Nm 3 2 m kg 23 ft lb LOC...

Page 294: ...GENERATOR AND STARTER CLUTCH 5 33 NOTE Tighten the generator cover bolts in stages and in a crisscross pattern ...

Page 295: ...ator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 28 1 Pickup rotor cover 1 2 Pickup rotor cover gasket 1 3 Dowel pin 2 4 Crankshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT New New 2 1 6 3 3 5 4 LT 6 LS T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 45 ...

Page 296: ...ckup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup rotor bolt 45 Nm 4 5 m kg 32 ft lb...

Page 297: ...UP ROTOR 5 36 4 Install Pickup rotor cover gasket Pickup rotor cover NOTE Tighten the pickup rotor cover bolts in stages and in a crisscross pattern T R Pickup rotor cover bolt 12 Nm 1 2 m kg 8 7 ft lb New ...

Page 298: ...IC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure ...

Page 299: ...arks 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat along with brushes 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 10 Collar 1 11 O ring 2 12 Starter motor yoke 1 13 Armature assembly 1 For assembly reverse the disassembly pro cedure ...

Page 300: ...s 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 23 5 mm 0 93 in Mica ...

Page 301: ...ASSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 NOTE Align the slot a on the brush seat with the tab b in the starter motor front cover 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers ...

Page 302: ...AL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the removal proce dure LT 3 4 5 2 1 10 5 3 New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 303: ...h rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 8 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Friction plate 3 1 Inside diameter 135 mm 5 31 in 13 Clutch damper spring 1 14 Clutch damper spring seat 1 15 Lock washer 1 16 Clutch boss 1 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R...

Page 304: ...1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 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 E 9 12 11 ...

Page 305: ...reservoir cap 1 2 Clutch master cylinder reservoir diaphragm holder 1 3 Clutch master cylinder reservoir diaphragm 1 4 Clutch lever 1 5 Clutch master cylinder push rod pin 1 6 Clutch switch coupler 1 Disconnect 7 Clutch hose union bolt 1 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch switch 1 11 Clutch master cylinder holder 1 12 Clutch master cylinder 1 For installation reverse the remova...

Page 306: ...the clutch master cylinder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 307: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 308: ...to remove Q ty Remarks 1 Clutch release cylinder piston 1 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 5 Clutch release cylinder body 1 For assembly reverse the disassembly pro cedure 5 2 3 1 4 New T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 309: ...ded screwdriver into one of the holes of the clutch housing and primary driven gear and then rotate the inner primary driven gear until both primary drive gears are aligned The teeth of both primary driven gears must be aligned for installation Insert two 5 mm bolts 2 into the spacer and then remove the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure ap...

Page 310: ...HECKING THE CLUTCH HOUSING 1 Check 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 o...

Page 311: ... Replace the clutch housing and crankshaft as a set EAS25250 INSTALLING THE CLUTCH 1 Install Clutch housing 1 NOTE Make sure that the projections a in the clutch housing align with the slots b in the oil pump drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Insert a cross headed screwdriver into one of the holes of the clutch housing and prima...

Page 312: ...E First install a friction plate and then alternate be tween a clutch plate and a friction plate 8 Install Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Rear balancer weight Refer to BALANCERS on page 5 103 10 Install Clutch cover NOTE Tighten the clutch cover bolts in the proper tight ening sequence as shown EAS25280 DISASSEMBLING THE CLU...

Page 313: ...he clutch mas ter cylinder Clutch fluid delivery passage clutch master cylinder body Obstruction Blow out with compressed air 2 Check Clutch master cylinder Clutch master cylinder kit Rust scratches wear Replace the clutch master cylinder and clutch master cylinder kit as a set 3 Check Clutch master cylinder reservoir Cracks damage Replace Clutch master cylinder reservoir diaphragm Damage wear Rep...

Page 314: ... is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean u...

Page 315: ...e cleaned and lubricated with clean or new clutch fluid Never use solvents on internal clutch com ponents as they will cause the piston seal to swell and distort Whenever a clutch release cylinder is dis assembled replace the piston seal EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1 Check Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P61017 Proper clutch hose routing is es...

Page 316: ...clutch fluid and could cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure that the top of the reservoir is horizontal 3 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 4 Check Clutch fluid ...

Page 317: ...ve Q ty Remarks Clutch housing Refer to CLUTCH on page 5 41 1 Oil baffle plate 1 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal proce dure ...

Page 318: ... EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 NOTE Hook the end of the shift shaft spring onto the shift shaft spring stopper 2 3 Install Shift arm 1 NOTE Align the punch mark a in...

Page 319: ...s Refer to THROTTLE BODIES on page 7 4 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Sidestand Refer to SHAFT DRIVE on page 4 87 Water pump Refer to WATER PUMP on page 6 10 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil pan 1 4 Oil pan gasket 1 5 Dowel pin 2 6 Oil delivery pipe 2 1 7 Oil delivery pipe 3 1 8 Oil strainer 1 9 Dowel pin 2 10 Oil pump 1 ...

Page 320: ...OIL PUMP 5 59 11 Relief valve assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 321: ... Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump driven sprocket 1 8 Oil pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 322: ... and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Li...

Page 323: ... 2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 61 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan NOTE Tighten the oil pan bolts in s...

Page 324: ...on page 5 58 1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 ...

Page 325: ...acer 1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear Order Job Parts to remove Q ty Remarks ...

Page 326: ... middle drive shaft assembly Order Job Parts to remove Q ty Remarks 1 Spring retainer 2 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly reverse the disassembly pro cedure ...

Page 327: ...ly Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Middle driven pinion gear nut 1 3 Middle driven shaft 1 4 Middle driven pinion gear 1 5 Bearing retainer 1 6 Bearing 1 7 Middle driven shaft bearing housing 1 For assembly reverse the disassembly pro cedure ...

Page 328: ...e the bearing retainer EAS25750 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Remove Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 remove the spring retain ers EAS25770 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Remove Middle driven pinion gear nut a Straighten the thread on the middle driven pinion gear nut b Loosen the middle driven pinion gear ...

Page 329: ...790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check Middle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS25800 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS25820 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing...

Page 330: ...860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Tighten Bearing retainer 1 a Attach the bearing retainer wrench 2 b Tighten the bearing retainer to specification c Lock the threads with a drift punch 2 Install Lock washer 1 Middle drive pinion gear nut 2 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb T R Middle driven pinion gear nut 110 Nm 11 0 m kg 80 ft lb LOCTITE 1 New Bearing retainer wrench...

Page 331: ...ddle driven shaft bearing housing bolts NOTE Finger tighten the middle driven shaft bearing housing bolts 2 Tighten Middle driven shaft bearing housing bolts NOTE Before tightening the bolts 1 Adjust the middle gear backlash Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 71 2 Check that the middle gears turns smoothly ET3P61025 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install Middle gear cas...

Page 332: ...tle middle gear backlash and damage the middle gears If the bolts are overtightened loosen them until the crankcase to middle driven shaft bearing housing clearance is within specification as stated below Then repeat all of the previous steps NOTE Tighten the middle driven shaft bearing hous ing bolts carefully one thread turn at a time only Push in the middle driven shaft bearing housing and then...

Page 333: ...THE MIDDLE GEAR BACKLASH on page 5 71 EAS25930 ALIGNING THE MIDDLE GEAR NOTE Aligning the middle gear is necessary when any of the following parts are replaced Crankcase Middle drive shaft Middle driven shaft bearing housing 1 Select Middle drive pinion gear shim s 1 Middle driven pinion gear shim s 2 NOTE Select the middle driven gear shim s 2 by cal culating the middle drive gear shim thickness ...

Page 334: ... 34 e Measured value f a numeral on the lower crankcase to be divided by 100 and added to 87 Example If the middle driven pinion gear is marked 03 d is 33 97 i e 34 00 0 03 33 97 e is 54 49 If the lower crankcase is marked 95 f is 87 95 i e 87 00 0 95 87 95 B 33 97 54 49 87 95 0 51 Round off to the hundredths digit and select the appropriate shim s NOTE In the above example the calculated number i...

Page 335: ...fer to MIDDLE GEAR on page 5 63 Clutch housing Refer to CLUTCH on page 5 41 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Gear position switch 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specif...

Page 336: ... Q ty Remarks T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New LS T R 4 Nm 0 4 m kg 2 9 ft Ib E E E E E E E E LT LT LT 8 10 10 7 6 5 4 1 2 3 10 9 4 10 10 2 2 ...

Page 337: ...ivery pipe 1 1 3 Plate 1 4 Oil baffle plate 3 1 5 Bearing 1 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter cartridge bolt 1 11 Upper crankcase damper 1 12 Crankcase plug 1 10 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 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 10 Nm 1 0 m kg 7 2 ft Ib T R 7...

Page 338: ... to remove Q ty Remarks 10 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 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 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 Nm 1 2 m kg 8 7 ft Ib 11 E T R 20 Nm 2 0 m kg 14 ft Ib 3 ...

Page 339: ... Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25600 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe Damage Replace Obstruction Wash and blow out with com pressed air ET3P61026 CHECKING THE BEAR...

Page 340: ...ightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts NOTE Lubricate the bolts 1 10 thread and wash ers with engine oil Lubricate the bolts 11 31 thread part and mating surface with engine oil Apply locking agent LOCTITE to the threads of the bolt 16 Finger tighten the crankcase bolts M9 115 mm bolts ...

Page 341: ...own WARNING EW3P61014 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again CAUTION EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bolt note that the angle from one corner to ...

Page 342: ... in the proper tight ening sequence as shown T R Crankcase bolt 11 12 24 Nm 2 4 m kg 17 ft lb Crankcase bolt 13 14 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt 15 31 10 Nm 1 0 m kg 7 2 ft lb 13 21 18 15 16 17 20 19 22 14 24 29 30 23 25 31 28 26 27 11 12 ...

Page 343: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure ...

Page 344: ...put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the...

Page 345: ...nce Out of specification Replace 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 Bore 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum...

Page 346: ...Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 5 mm 0 20 in Piston ring Top ring End gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in 2nd ring End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 047...

Page 347: ... in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolt threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank sh...

Page 348: ... Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer s marks face up 2 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod is facing to the left when the punch mark ...

Page 349: ...Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with piston ring compressor 2 install the connecting rod assembly 1 into the cylinder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the cran...

Page 350: ...rod nuts further to reach the specified angle 115 125 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again CAUTION ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle NOTE On a hexagonal ...

Page 351: ... to CRANKCASE on page 5 74 Front balancer weight Refer to BALANCERS on page 5 103 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 82 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 3 1 2 2 E E New 4 LS ...

Page 352: ...ankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank sh...

Page 353: ...ication select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the lower crank case and the numbers B stamped into the crankshaft web are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the lower crankcase and crankshaft web illustration If J1 J5 are the same use the same si...

Page 354: ...CRANKSHAFT 5 93 NOTE Align the projections a on the crankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place ...

Page 355: ...marks Crankcase Separate Refer to CRANKCASE on page 5 74 Stopper lever Refer to SHIFT SHAFT on page 5 56 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long shift fork guide bar 1 7 Shift fork L 1 8 Shift fork R 1 9 Short shift fork guide bar 1 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 ...

Page 356: ...TRANSMISSION 5 95 13 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 357: ... 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 12 Bearing 1 13 Main axle bearing housing 1 For assembly reverse the disassembly pro cedure 13 12 11 10 9 New New New New 7 8 7 6 5 4 3 2 1 6 E M M M M ...

Page 358: ...nd wheel gear 1 4 Collar 1 5 Washer 1 6 5th wheel gear 1 7 Circlip 2 8 Toothed washer 2 9 3rd wheel gear 1 10 Toothed spacer 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Washer 1 15 1st wheel gear 1 16 Bearing 1 17 Washer 1 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 359: ... 98 18 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 360: ...to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar 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 Re...

Page 361: ...30 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 NOTE With the toothed lock washer retainer...

Page 362: ...ng bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 3 Install Washer 1 NOTE Install the washer with its chamfered side facing towards t...

Page 363: ...g pin 1 must face towards the rear of the upper crankcase Make sure the bearing circlip 2 is inserted into the groove in the upper crankcase 5 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly 1 2 ...

Page 364: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Front balancer lever 1 2 Front balancer shaft 1 3 Washer 2 4 Bearing 2 5 Front balancer gear 1 6 Damper 4 7 Front balancer weight 1 For installation reverse the removal proce dure ...

Page 365: ...7 4 Pickup rotor cover Refer to PICKUP ROTOR on page 5 34 Clutch cover Refer to CLUTCH on page 5 41 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft 1 5 Washer 2 6 Bearing 2 7 Rear balancer gear 1 8 Damper 4 9 Rear balancer weight 1 For installation reverse the removal proce dure ...

Page 366: ...ach damper is positioned to the outside of the gear projec tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating sur...

Page 367: ...rom the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale ET3P61033 INSTALLING THE REAR BALANCER 1 Install Rear balancer gear 1 Dampers 2 Rear balancer weight 3 Bearings Washers NOTE Install the dampers onto the balancer gear so that the middle section a of each damper is positioned to the outside of th...

Page 368: ...haft a Align the punch marks a in the balancer weight with the punch mark b in the upper crankcase b Align the balancer gear punch mark c with the primary driven gear point d as shown NOTE Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the projection e on the up per crankcase Make sure that...

Page 369: ... Rear balancer lever bolt 1 Rear balancer shaft pinch bolt 2 NOTE Make sure that the balancer shaft does not ro tate 7 Start the engine and check that there is no abnormal noise coming from the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale T R Rear balancer shaft 0 4 Nm 0 04 m kg 0 29 ft lb f e c 2 ...

Page 370: ...BALANCERS 5 109 ...

Page 371: ...OOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 ...

Page 372: ...nt reservoir 1 6 Radiator inlet hose 1 7 Plunger control unit hose 2 1 8 Oil cooler outlet hose 1 9 Left horn low 1 10 Coolant reservoir bracket 1 11 Water pump breather hose 1 12 Radiator outlet hose 1 13 Right horn high 1 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 kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 373: ... 1 21 Air deflector 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks 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 kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 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 LT LT LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 6 7 8 3 9 10 11 13 14...

Page 374: ...and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 37 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure ...

Page 375: ...rain Refer to CHANGING THE COOLANT on page 3 19 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal proce dure ...

Page 376: ...r thinner 2 Install O ring Oil cooler NOTE Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 13 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator...

Page 377: ...nect 3 Radiator inlet hose 1 Disconnect 4 Thermostat inlet hose 2 1 5 Thermostat cover radiator filler pipe 1 6 Thermostat housing 1 7 Thermostat 1 8 Thermostat inlet pipe 2 1 9 Thermostat inlet hose 1 1 10 Plunger control unit hose 1 1 11 Coolant temperature sensor coupler 1 Disconnect 12 Coolant temperature sensor 1 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 18 Nm 1 8 m kg 13 ...

Page 378: ...tion reverse the removal proce dure Removing the thermostat assembly Order Job Parts to remove Q ty Remarks 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 18 Nm 1 8 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New 1 10 13 12 11 2 7 5 3 4 6 8 9 3 ...

Page 379: ...at pipes Radiator inlet hose Thermostat cover radiator filler pipe Plunger control unit hose 1 Cracks damage wear Replace EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant temperature sensor CAUTION EC3P61019 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Thermostat ho...

Page 380: ...THERMOSTAT 6 9 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 381: ...ant level is extremely low or the coolant contains engine oil Right side cowling Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 For installation reverse the removal proce dure ...

Page 382: ...arts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 10 Water pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 383: ...r pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 CAUTION ECA14080 Never lubricate the ...

Page 384: ...es smoothly EAS26580 INSTALLING THE WATER PUMP 1 Install O ring 1 Water pump assembly 2 NOTE Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket Lubricate the O ring with a thin coat of lithium soap base grease Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver 40 mm YM 0...

Page 385: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 386: ...WATER PUMP 6 15 ...

Page 387: ... PUMP 7 2 INSTALLING THE FUEL TANK 7 2 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 7 CHECKING THE THROTTLE BODIES 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE PRESSURE REGULATOR 7 13 CHECKING THE AIR INDUCTION SYSTEM 7 13 INSTALLING THE AIR INDUCTION SYSTEM 7 13 ...

Page 388: ...nk panel 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank breather hose 1 5 Fuel tank overflow hose 1 6 Fuel hose holder 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal proce dure T R 16 Nm 1 6 m kg 11 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 5 4 3 7 6 8 9 2 6 ...

Page 389: ...el 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 EAS26700 INSTALLING THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always u...

Page 390: ...ng the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose After installing the fuel hose holder 1 make sure that the sections a b and c of the ...

Page 391: ... THE COOLANT on page 3 19 1 O2 sensor coupler 1 Disconnect 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness coupler 1 Disconnect 4 Engine idle speed adjusting screw 1 Disconnect 5 Throttle body joint clamp screw 8 Loosen 6 Throttle bodies 1 7 Throttle cable accelerator cable 1 Disconnect 8 Throttle cable decelerator cable 1 Disconnect 9 Plunger control unit hose 1 1 Disconn...

Page 392: ...Disconnect 11 Throttle body joint 4 For installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib 5 5 5 5 11 11 11 5 5 5 5 11 9 10 1 2 4 8 7 6 3 ...

Page 393: ... 3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 1 8 Negative pressure hose 7 9 Bypass air unit inlet hose 1 10 Bypass air unit 1 11 Bypass air unit outlet hose 4 12 Intake air pressure sensor 1 13 Fuel rail 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse the removal proce dure 12 3 4 5 6 1 7 2 8 8 8 8 9 8 8 8 14 15 11 11 11 13 1...

Page 394: ...ause fuel to spurt out when removing the hoses c Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel rail 2 d Connect the pressure gauge 4 to fuel pres sure adapter 3 e Start the engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be proper...

Page 395: ...at the voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 to specification Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Output voltage at idle 0 63 0 73 V T R Throttle position sensor screw 3 5 Nm 0 35 m kg 2 53 ft lb 3 2 1 ...

Page 396: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6 ...

Page 397: ...ver 3 Air induction system hose air cut off valve to 3 way joint 4 Air induction system hose 3 way joint to air cut off valve 5 Air cut off valve 6 Air induction system hose 3 way joint to hose plug 7 Air induction system hose air filter case joint assembly to 3 way joint 8 Air filter case joint asssembly ...

Page 398: ... Disconnect 2 Air induction system hose air filter case joint assembly to 3 way joint 1 3 Air induction system hose 3 way joint to hose plug 1 4 Air induction system hose 3 way joint to air cut off valve 1 5 Air induction system hose 3 way joint to reed valve cover 4 6 Air induction system hose air cut off valve to 3 way joint 2 7 Air cut off valve 1 For installation reverse the removal proce dure...

Page 399: ...t inlet pipe 1 Refer to THERMOSTAT on page 6 6 1 Reed valve cover cylinder 1 1 2 Reed valve cover cylinders 2 3 1 3 Reed valve cover cylinder 4 1 4 Reed valve assembly 4 5 Reed valve plate 4 For installation reverse the removal proce dure LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 T R 14 Nm 1 4 m kg 10 ft Ib ...

Page 400: ... valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipe...

Page 401: ... LIGHTING SYSTEM 8 21 CIRCUIT DIAGRAM 1 2 8 21 CIRCUIT DIAGRAM 2 2 8 23 TROUBLESHOOTING 8 25 SIGNALING SYSTEM 8 27 CIRCUIT DIAGRAM 1 2 8 27 CIRCUIT DIAGRAM 2 2 8 29 TROUBLESHOOTING 8 31 COOLING SYSTEM 8 37 CIRCUIT DIAGRAM 8 37 TROUBLESHOOTING 8 39 FUEL INJECTION SYSTEM 8 41 CIRCUIT DIAGRAM 1 2 8 41 CIRCUIT DIAGRAM 2 2 8 43 ECU SELF DIAGNOSTIC FUNCTION 8 45 SELF DIAGNOSTIC FUNCTION TABLE 8 46 TROUB...

Page 402: ...NE 8 121 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 8 122 BASIC PROCESS FOR TROUBLESHOOTING 8 123 A CHECKING THE ABS WARNING LIGHT 8 124 B 1 THE ABS WARNING LIGHT DOES NOT COME ON 8 124 B 2 THE ABS WARNING LIGHT REMAINS ON 8 124 B 3 THE ABS WARNING LIGHT FLASHES 8 124 B 4 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PAST MALFUNCTION 8 124 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCT...

Page 403: ...AFT POSITION SENSOR 8 162 CHECKING THE LEAN ANGLE SENSOR 8 163 CHECKING THE STARTER MOTOR OPERATION 8 163 CHECKING THE STATOR COIL 8 164 CHECKING THE RECTIFIER REGULATOR 8 164 CHECKING THE HORNS 8 165 CHECKING THE OIL LEVEL SWITCH 8 165 CHECKING THE FUEL SENDER 8 166 CHECKING THE RADIATOR FAN MOTORS 8 166 CHECKING THE COOLANT TEMPERATURE SENSOR 8 167 CHECKING THE THROTTLE POSITION SENSOR 8 167 CHE...

Page 404: ... DARK GREEN L Y B R R L R G G Y Sb R B B Y R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O C C B C A A A A A A A C C C C C A A A A A D B B B A SUB WIRE HARNESS B D W B Gy Gy W B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy ...

Page 405: ...ss 17 Coupler 2 wire harness front cowling wire harness 31 Coupler 3 wire harness front cowling wire harness 32 Sidestand switch 33 Cylinders 1 4 ignition coil 34 Spark plug 35 Cylinders 2 3 ignition coil 41 ECU engine control unit 42 Crankshaft position sensor 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse ...

Page 406: ... R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W...

Page 407: ...ing wire harness wire harness 17 Coupler 2 front cowling wire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 79 Relay unit 95 Lean angle sensor ...

Page 408: ... a spark However the engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8...

Page 409: ...ge 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 162 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 161 Replace the spark plug cap s 6 Check ...

Page 410: ... 8 149 Replace the gear position switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 160 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 163 Replace the lean angle sensor 14 Check the entire ignition system...

Page 411: ...IGNITION SYSTEM 8 8 ...

Page 412: ...Br R R W G O C C B C A A A A A A A C C C C C A A A A A D B B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B B L W B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BL...

Page 413: ...attery 10 Starter relay 11 Starter motor 13 Gear position switch 17 Coupler 2 wire harness front cowling wire harness 31 Coupler 3 wire harness front cowling wire harness 32 Sidestand switch 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse ...

Page 414: ...Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R Sb W L Y Sb...

Page 415: ...ont cowling wire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 70 Start switch 73 Clutch switch 79 Relay unit 80 Starting circuit cut off relay ...

Page 416: ...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 been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 13 1 12 4 5 7 7 a b 9 7 10 8 6 2 3 11 a WHEN THE...

Page 417: ...charge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 163 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 39 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHEC...

Page 418: ...page 8 149 Replace the gear position switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the right handlebar switch 14 Check the entire starting system wiring Refer...

Page 419: ...ELECTRIC STARTING SYSTEM 8 16 ...

Page 420: ...W Br R Br L Br L Br W B W W L L R R R G R W W W W ON OFF P R Br L B R R R Br L B Br R Br R W W W GRAY B R BLACK R R L W R L R W G W B R L B DARK GREEN A A A A A A A B2 B1 B1 BB Lg W B B Lg W R Y G L R Y Y W G L R B R B G L B L Br W BLACK GREEN B L G W W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L BLUE BLUE B G B W R G R W G B Y L B W BB B Y L Lg R W ...

Page 421: ...CHARGING SYSTEM 8 18 2 Rectifier regulator 3 AC magneto 7 Main fuse 8 Battery ...

Page 422: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 164 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 164 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGR...

Page 423: ...CHARGING SYSTEM 8 20 ...

Page 424: ...B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A A A A A D B B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B B L W B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B ...

Page 425: ...6 License plate light 28 Tail brake light 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 53 Headlight relay on off 54 Hazard lighting fuse 56 Headlight fuse 57 Ignition fuse ...

Page 426: ...W Br R B B R B R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R...

Page 427: ...r 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 74 Pass switch 75 Dimmer switch 90 Meter light 91 High beam indicator light 99 Headlight relay dimmer 101 Auxiliary light 102 Headlight ...

Page 428: ... fuses Main headlights ignition and haz ard lighting Refer to CHECKING THE FUS ES on page 8 153 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHE...

Page 429: ...efer to CHECKING THE RE LAYS on page 8 157 Replace the headlight relay dimmer 9 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 21 and CIRCUIT DIA GRAM 2 2 on page 8 23 Properly connect or repair the lighting sys tem wiring Replace the ECU ...

Page 430: ...C A A A A A A A C C C C C A A A A A D B B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W BROWN B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B ...

Page 431: ...ic control unit 21 Rear wheel sensor 24 Rear brake light switch 25 Brake light relay 28 Tail brake light 29 Rear left turn signal light 30 Rear right turn signal light 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 49 Coupler 4 wire harness front cowling wire harness 50 Oil level switch 52 Coupler 5 wire harness front cowling wire harness 54 Hazard lighting fuse 55...

Page 432: ... R L Y B Y Sb G Y R B UP DOWN R L W R B W L R L L W L Y R W L G B R Sb B Y Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br R B B R B R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY L...

Page 433: ...ness 52 Coupler 5 front cowling wire harness wire harness 65 Turn signal hazard relay 68 Front brake light switch 71 Hazard switch 77 Turn signal switch 78 Horn switch 79 Relay unit 84 Neutral indicator light 87 Multi function meter 88 Oil level warning light 92 Right turn signal indicator light 93 Left turn signal indicator light 96 Horn 97 Front left turn signal light 98 Front right turn signal ...

Page 434: ... ABS ECU Refer to CHECKING THE FUS ES on page 8 153 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 ...

Page 435: ...CHECKING THE BULBS AND BULB SOCKETS on page 8 152 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the rear brake light switch 4 Check the brake light relay Refer to CHECKING THE RE LAYS on pa...

Page 436: ... Check the hazard switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the left handlebar switch 4 Check the turn signal hazard relay Refer to CHECKING THE TURN SIGNAL HAZARD RELAY on page 8 160 Replace the turn signal hazard relay 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signali...

Page 437: ...e 8 149 Replace the gear position switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 165 Replace the oil level switch 2 Check the entire signaling system wiring ...

Page 438: ...ellow blue yellow blue 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Replace the rear wheel sensor 2 Check the entire speed sensor wir ...

Page 439: ...SIGNALING SYSTEM 8 36 ...

Page 440: ... A A C C C C C A A A A A D B B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WI...

Page 441: ...in fuse 8 Battery 41 ECU engine control unit 44 Coolant temperature sensor 57 Ignition fuse 60 Radiator fan motor relay 61 Left radiator fan motor fuse 62 Left radiator fan motor 63 Right radiator fan motor fuse 64 Right radiator fan motor ...

Page 442: ...ls Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 166 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 157 Replace the radiator fan motor relay 6 Check the coo...

Page 443: ...COOLING SYSTEM 8 40 ...

Page 444: ...Br R R W G O C C B C A A A A A A A C C C C C A A A A A D B B B A B D W B Gy W B2 B1 B1 BB Lg W B B Lg W W B Gy W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L ...

Page 445: ...park plug 35 Cylinders 2 3 ignition coil 36 Injector 4 37 Injector 3 38 Injector 2 39 Injector 1 40 Air induction system solenoid 41 ECU engine control unit 42 Crankshaft position sensor 43 Intake air temperature sensor 44 Coolant temperature sensor 45 O2 sensor 46 Cylinder identification sensor 47 Throttle position sensor 48 Intake air pressure sensor 52 Coupler 5 wire harness front cowling wire ...

Page 446: ...B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br ...

Page 447: ...wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 74 Pass switch 75 Dimmer switch 79 Relay unit 81 Fuel pump relay 87 Multi function meter 89 Engine trouble warning light 95 Lean angle sensor 99 Headlight relay dimmer 102 Headlight ...

Page 448: ...ode 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 The engine trouble warning light comes on for 1 4 seconds after the main switch has ...

Page 449: ...ode No Item Symptom Able un able to start Able un able to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor Unable Unable 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit dete...

Page 450: ...ty cylin ders Able depending on the number of faulty cylin ders 34 Cylinders 2 3 igni tion coil faulty ignition Malfunction detected in the prima ry wire of the cylinders 2 3 igni tion coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 R...

Page 451: ...malfunc tion Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Unable Unable Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output signal error No signals are received from the E...

Page 452: ...ore NOTE All displays on the meter disappear except the odometer tripmeter fuel reserve tripmeter displays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagno...

Page 453: ...nals are re ceived from the crankshaft position sensor Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction in ECU Improperly installed crankshaft position sensor 13 Intake air pressure sensor open or short circuit detect ed Open or short circuit in sub wire harness Open or short circuit in wire harness Defective intake air pressure sen...

Page 454: ...ed No normal signal is re ceived from the lean angle sensor The vehicle has overturned Defective lean angle sensor Malfunction in ECU Improperly installed lean angle sensor 08 31 The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the upper lim it lean air fuel ratio Open or short circuit in sub wire harness Open or short circuit in front cowling wire h...

Page 455: ...ear wheel sensor detected Defective gear position switch Malfunction in the engine side of the gear position switch Malfunction in ECU Malfunction in ABS ECU 07 21 43 The ECU is unable to moni tor the battery voltage an open or short circuit in the line to the ECU Open or short circuit in front cowling wire harness Open or short circuit in wire harness Malfunction in ECU 09 44 An error is detected...

Page 456: ...cking method 01 Throttle angle Fully closed position 15 17 Check with throttle fully closed Fully opened position 97 100 Check with throttle fully open 03 Pressure difference atmospheric pressure and intake air pressure Displays the intake air pres sure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK 05 Intake air temperature Display...

Page 457: ...ar position switch Shift the transmission Neutral ON In gear OFF 60 EEPROM fault code dis play No history 00 History exists 01 04 Cylinder fault code If more than one cylinder is defective the display alter nates every two seconds to show all the detected cylin der numbers When all cyl inder numbers are shown the display repeats the same process 61 Malfunction history code display No history 00 Hi...

Page 458: ...lluminates the engine trou ble warning light Check the spark five times Connect an ignition checker 31 Cylinders 2 3 ignition coil Actuates the cylinders 2 3 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the en...

Page 459: ...uminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel pump relay five times 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light...

Page 460: ...ation sensor Check for looseness or pinching Starting the en gine and oper ating it at idle 2 Connections Cylinder identification sensor cou pler Wire harness ECU coupler Sub wire harness 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 se curely 3 Open or short circuit in wire harne...

Page 461: ...ns Crankshaft position sensor coupler 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 se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray b...

Page 462: ...efective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 168 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Diagnostic code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 ...

Page 463: ...coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and r...

Page 464: ...CU coupler Sub wire harness 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 se curely 3 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yellow Open circuit item Output voltage Ground wi...

Page 465: ... may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely If the transmis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wiring 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between ECU and black ...

Page 466: ...t temperature sensor coupler 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 se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler black blue black blue gr...

Page 467: ...r temperature sensor cou pler 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 se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler black blue black blu...

Page 468: ...CU coupler Sub wire harness coupler Front cowling wire harness 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 se curely 3 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 senso...

Page 469: ...e engine can not be restarted unless the main switch is first turned OFF 2 Installed condition of lean angle sen sor Check the installed direction and condition of the sensor 3 Connections Lean angle sensor coupler 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 se ...

Page 470: ...is a malfunction repair it and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 senso...

Page 471: ...efer to CHECKING THE FUEL PRESSURE on page 7 7 Check the throttle position sen sor Execute the diagnostic mode Code No 01 Replace if defective Check the fuel system discon nection etc Repair or replace if there is a malfunction Check the intake system im proper sealing etc Repair or replace if there is a malfunction Fault code No 31 Symptom The amount of air fuel ratio feedback compensation is mai...

Page 472: ...and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler b...

Page 473: ... 7 7 Checking the throttle position sensor Execute the diagnostic mode Code No 01 Replace if defective Checking the fuel system clog ging etc Repair or replace if there is a malfunction Fault code No 32 Symptom The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Diagnostic code No 01 Throttle position sensor Order Ite...

Page 474: ...locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 1 4 igni tion coil connector and ECU coupler orange orange Between cylinders 1 4 igni tion coil connect...

Page 475: ...ocking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 2 3 igni tion coil connector and ECU coupler gray red gray red Between cylinders 2 3 igni tion coil conn...

Page 476: ...y pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green ...

Page 477: ...ng condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and input ting the vehicle speed signals by operating the vehicle at a 20 to 30 km h A 2 Open or short circuit in wire harness and or ABS wire harness Repair or replace if there is an open or short circuit Between rear wheel sensor coupler and ABS ECU coupler white white black bla...

Page 478: ...en gear position switch coupler and relay unit coupler sky blue sky blue Between relay unit coupler and ECU coupler black yellow black yellow B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 94 B 4 Defective gear position switch neutral circuit Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 149 ...

Page 479: ...f the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in the wire har ness and or sub wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler blue yellow blue yellow red blue red blue Between relay unit coupler and main switch coupler red brown...

Page 480: ...s exhaust gas volume 1 Execute the diagnostic mode Code No 60 to check the faulty cylinder number If multiple cylinders are defec tive the numbers of the faulty cylinders are displayed alternately at 2 second inter vals 2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cyl inder to 0 Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 7 Replace ECU if it does not re cov...

Page 481: ...n page 8 154 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 17 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and ignition fuse brown blue brown blue Between ignition fuse and ECU coupler red white red white Fault code No 50 Symp...

Page 482: ...lue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Che...

Page 483: ...lue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Check...

Page 484: ...B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A A A A A D B B B B D W B Gy W B2 B1 B1...

Page 485: ...Main switch 5 Fuel injection system fuse 7 Main fuse 8 Battery 15 Fuel pump 17 Coupler 2 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse ...

Page 486: ...W Br R B B R B R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R...

Page 487: ...FUEL PUMP SYSTEM 8 84 17 Coupler 2 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 79 Relay unit 81 Fuel pump relay ...

Page 488: ...charge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 157 Replace the relay unit 6 Check the fuel pump Refer to CHECKING TH...

Page 489: ...FUEL PUMP SYSTEM 8 86 ...

Page 490: ...G R Lg Sb Br R R W G O C C B C A A A A A A A C C C C C A A A A A D B B B A B D W B Gy W B2 B1 B1 BB Lg W B B Lg W W B Gy W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK ...

Page 491: ... switch 6 Backup fuse odometer clock immobilizer system and windshield drive system 7 Main fuse 8 Battery 17 Coupler 2 wire harness front cowling wire harness 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse ...

Page 492: ... W Br R B B R B R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B ...

Page 493: ...WINDSHIELD DRIVE SYSTEM 8 90 17 Coupler 2 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 76 Windshield position switch 105 Windshield drive unit ...

Page 494: ...CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the windshield position switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the left handlebar switch 5 Check the entire windshield drive system wiring Refer to CIRCU...

Page 495: ...WINDSHIELD DRIVE SYSTEM 8 92 ...

Page 496: ...R Br L Br L Br W B W W R R R G R W W W W ON OFF P BLUE BLUE R Br L B B G R R R Br L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB B Y L Lg R W R G B2 B2 B1 B1 BB Lg W B B Lg W R Br B R W G Y R Y G L R Y Y W G L R B R B G L B B L Gy W R L BLACK B L W B BLACK W L Y B L L W B B L L Y B L BLACK P W B L L BLACK B B B B BB2 BB1 BB4 BB3 W W W W R Br R W G L L W R Y R B L R B...

Page 497: ...ACCESSORY BOX SYSTEM 8 94 1 Main switch 7 Main fuse 8 Battery 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse ...

Page 498: ... R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK B B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W Dg Ch B B Dg Br G L B Ch B Dg Br G C...

Page 499: ...ACCESSORY BOX SYSTEM 8 96 52 Coupler 5 front cowling wire harness wire harness 82 Accessory box solenoid ...

Page 500: ...NG THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 169 Replace the accessory box solenoid 5 Check the entire accessory box system wiring Refer to CIRCUIT DIAGRAM...

Page 501: ...ACCESSORY BOX SYSTEM 8 98 ...

Page 502: ... L B W R L B W R L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y...

Page 503: ...ve system 7 Main fuse 8 Battery 12 Immobilizer unit 14 Coupler 1 wire harness front cowling wire harness 17 Coupler 2 wire harness front cowling wire harness 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse ...

Page 504: ... L Y B Y Sb G Y R B UP DOWN R L W R B W L R L L W L Y R W L G B R Sb B Y Sb W Sb B Lg Br R R Br B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B...

Page 505: ...ing wire harness wire harness 17 Coupler 2 front cowling wire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 86 Immobilizer system indicator light 87 Multi function meter ...

Page 506: ... key 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 pl...

Page 507: ...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 508: ...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 509: ...m indicator light does not come on nor flashes a Main switch ON b 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 s...

Page 510: ... to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 99 and CIRCUIT DIA GRAM 2 2 on page 8 101 Properly connect or repair the immobilizer system wiring Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 107 Fault code Par...

Page 511: ...nit mal function 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 ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure Th...

Page 512: ...IMMOBILIZER SYSTEM 8 109 a Light on b Light off ...

Page 513: ...IMMOBILIZER SYSTEM 8 110 ...

Page 514: ... R R R Br L B W R L B W R L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L ...

Page 515: ...nt cowling wire harness 18 ABS test coupler 19 ABS ECU electronic control unit 20 Front wheel sensor 21 Rear wheel sensor 22 ABS motor relay 23 Hydraulic unit 24 Rear brake light switch 25 Brake light relay 28 Tail brake light 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse 57 Ignition fus...

Page 516: ... Y B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK B B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W Dg Ch B B Dg Br G L B Ch B Dg Br...

Page 517: ...ont cowling wire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 68 Front brake light switch 69 Engine stop switch 70 Start switch 79 Relay unit 80 Starting circuit cut off relay 85 ABS warning light 87 Multi function meter ...

Page 518: ...U fuse 4 ABS motor fuse 5 ABS motor relay 6 ABS ECU electronic control unit 7 Hydraulic unit HU 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Left front brake caliper 12 Right front brake caliper partially operated together with the rear brake 13 Front wheel sensor 14 Front wheel sensor rotor 15 Proportioning valve 16 Metering valve ...

Page 519: ...ABS ANTI LOCK BRAKE SYSTEM 8 116 ...

Page 520: ... W W G B B R L W Y W P B Y R W G W Y L Sb W Y 6 5 W B Gy W R R W G G W B W R B R B B W R L B W R L W Y B G R Lg Sb W Sb Lg G R B W Y W Br W Y G W L L W B W Br B G Y B L W W L Y G Br W B Br B B W G Y L Y L Y W B Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W Y G W L G W P G R G B B R L Y B R R L R G G Y Sb R B B Y R G R L B R L Y B Y Sb G Y R B R Br R W G L L W R Y R B L R Br B G L R W Br Br B L...

Page 521: ...ABS test coupler 3 ABS motor relay coupler 4 Hydraulic unit solenoid coupler 5 ABS motor coupler 6 Rear wheel sensor coupler 7 ABS ECU coupler 8 Wire harness ABS wire harness coupler 9 Front wheel sensor coupler 10 Wire harness front cowling wire harness coupler ...

Page 522: ...b Parts to remove Q ty Remarks Rear side cover Refer to GENERAL CHASSIS on page 4 1 Storage compartment Refer to GENERAL CHASSIS on page 4 1 1 ABS ECU cover 1 2 ABS ECU coupler 2 Disconnect 3 ABS ECU 1 4 ABS motor relay coupler 1 Disconnect 5 ABS motor relay 1 For installation reverse the removal proce dure 4 5 3 2 2 1 ...

Page 523: ...hoses 1 Check Solenoid valve resistance Out of specification Replace the hydraulic unit NOTE Measure the resistance of the front brake rear brake and unified brake system solenoid valves a Connect the pocket tester Ω 1 to the sole noid valve terminals as shown b Measure the solenoid valve resistance 2 Check Solenoid valve insulation Continuity Replace the hydraulic unit a Connect the pocket tester...

Page 524: ...G EW3P61011 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 144 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function 2 ...

Page 525: ...are should be taken not to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU hydraulic unit wheel sensors and ABS motor relay are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the malfunction codes when the service is finished This is ...

Page 526: ...d C 5 The ABS warning light flashes every 0 5 second C 1 Only the ABS warn ing light does not come on C 3 The ABS warning light does not come on when pushing the start switch Check the test coupler adapter B 1 The ABS warning light does not come on B 3 The ABS warning light flashes B 2 The ABS warning light remains on B 5 Present malfunction B 4 Past malfunction A Check the ABS warning light C 2 A...

Page 527: ...4 ET3P61061 B 1 THE ABS WARNING LIGHT DOES NOT COME ON 1 Only the ABS warning light fails to come on when the main switch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 3 The ABS warning light fails to come on while the start switch is being pushed C 3 ET3P61062 B 2 THE ABS WARNING LIGHT REMAINS ON 1 A present malfunction is detected B 5 2 The ABS wa...

Page 528: ...lfunction codes delete the fuel injection system fault codes and then start the check again The test coupler adapter must be connected to the ABS test coupler to display the malfunction codes If the adapter is not connected the ABS warning light will come on or flash but no malfunction codes will be displayed EAS27870 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION Remove front...

Page 529: ...test coupler 2 Lock plate 3 Protective cap 4 Ground terminal black 5 T C terminal sky blue 6 T F terminal light green 7 ABS warning light terminal green red 8 Test coupler adapter 9 Light green lead 10 Black lead 11 White red lead A This example is the pattern for malfunction code 12 B This example is the pattern for malfunction code 21 C Time seconds ...

Page 530: ...t 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES on page 8 153 If the main fuse is blown replace the fuse 4 Wiring Check the entire multi function meter wiring Refer to CIRCUI...

Page 531: ...G LIGHT FLASHES EVERY 0 5 SECOND The ABS warning light flashes every 0 5 second if a malfunction code for a past malfunction is not stored in the memory of the ABS ECU The ABS warning light flashes quicker if a malfunction code is displayed on the multi function display If no malfunction code is displayed make sure that the custom er understands the possible conditions that may cause the ABS warni...

Page 532: ...stem wiring is defective properly connect or replace the ABS ECU couplers ABS wire harness front cowling wire harness and wire harness 6 Check the connection of the ABS wire harness to the ABS ECU Check that the ABS wire harness is securely connected to the ABS ECU Refer to ABS COUPLER LOCATION CHART on page 8 117 7 The ABS ECU ABS wire harness front cowling wire harness or wire harness couplers a...

Page 533: ...eel sensor rotor Malfunction code 11 See page 8 133 12 Rear wheel sensor signal is not re ceived properly Installation of the rear wheel sensor Rear wheel sensor lead and coupler ABS wire harness rear wheel sensor circuit Rear wheel sensor rotor Malfunction code 12 See page 8 133 13 26 14 27 Incorrect signal from the front 13 26 or rear 14 27 wheel sensor is detect ed 13 14 26 27 Installation of t...

Page 534: ... vehicle wheelies Installation of the front wheel sensor Wire harness and ABS wire harness front wheel sensor circuit Malfunction code 25 See page 8 137 41 Front wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is normal 41 Brake dragging Hydraulic unit operation tests Fr...

Page 535: ...it sole noid circuit Hydraulic unit solenoid cou pler Malfunction code 35 See page 8 141 51 Front wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is low Brake dragging Hydraulic unit operation tests Front wheel brake line Battery voltage Malfunction code 51 See page 8 14...

Page 536: ...SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 Front wheel sensor rotor is defective Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 c Front wheel sensor circuit is short circuited Front wheel sensor or lead is short circuited Refer to MAINTENANCE OF THE FR...

Page 537: ...epending on the condition Malfunction codes 13 26 front wheel and 14 27 rear wheel Incorrect signal from the front 13 26 or rear 14 27 wheel sensor is detected 1 The wheel sensors or sensor rotors are not properly installed a Installation of the front or rear wheel sensor Check that the wheel sensor is properly installed in the housing Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTO...

Page 538: ...OR ROTOR on page 4 22 and INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 23 Front or rear wheel sensor circuit is broken Refer to CIRCUIT DIAGRAM 1 2 on page 8 111 and CIRCUIT DIAGRAM 2 2 on page 8 113 ABS wire harness is disconnected from the ABS ECU coupler terminal Refer to MAINTENANCE OF THE ABS ECU on page 8 120 NOTE Check that both the front and rear wheel sensor couplers are connected ...

Page 539: ...d properly Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 5 Wire harness ABS wire harness and front cowling wire harness Check the front and rear brake light switch monitor circuits Check the green yellow lead for continuity between 1 and 2 of the front brake light switch monitor circuit Check the brown black lead for continuity between 3 and 4 of the rear brake light switch monitor c...

Page 540: ...HEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 Check if there is looseness between the housing and the wheel Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 3 Front wheel sensor circuit is short circuited Front wheel sensor or lead is short circuited R...

Page 541: ...om the hydraulic unit to the metering valve NOTE If the brake hose inlet and outlet connections are incorrect on the hydraulic unit the brake lever will be pulled to its full stroke position without responding and then it will be pushed back slowly without pulsating when the final check on page D 3 FINAL CHECK on page 8 144 is performed If the front and rear brake hose connections are reversed on ...

Page 542: ...e lines 4 Brake hose lines Check the brake hose lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EW3P61005 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and from the hydraulic...

Page 543: ... the ABS ECU coupler Refer to CIRCUIT DIAGRAM 1 2 on page 8 111 and CIRCUIT DIAGRAM 2 2 on page 8 113 4 ABS ECU If the malfunction is not corrected after checking items 1 to 3 replace the ABS ECU Malfunction code 32 ABS ECU circuit is broken or short circuited 1 ABS ECU circuit positive battery terminal to red white terminal of the ABS ECU coupler Turn the main switch to OFF and disconnect the ABS...

Page 544: ...nder the hydraulic unit is connected properly Check the ABS motor for continuity Refer to MAINTENANCE OF THE HYDRAULIC UNIT on page 8 120 2 ABS wire harness Disconnect the ABS motor coupler and then check for continuity between the black white terminal of the ABS motor coupler of ABS wire harness and the negative battery terminal Disconnect the ABS ECU couplers and then check for continuity betwee...

Page 545: ...2 2 Battery voltage Measure the battery output voltage EAS22830 D 1 DELETING THE MALFUNCTION CODES 1 Connect the test coupler adapter 1 to the ABS test coupler 2 Refer to B 5 MAL FUNCTION CHECK BY THE ABS SELF DI AGNOSIS PRESENT MALFUNCTION on page 8 125 2 Turn the main switch to ON Previously recorded malfunction codes will be displayed in the multi function display 3 Set the engine stop switch 1...

Page 546: ...tion codes af ter the service has been completed ET3P61020 D 2 DELETE FUNCTION TEST 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Connect the test coupler adapter to the ABS test coupler 4 Turn the main switch to ON 5 Check ABS ECU voltage Lower than 12 8 V Charge or replace the battery a Connect the pocket tester DC 20 V to the ABS ECU couplers b Measure the ABS ECU volta...

Page 547: ...NG THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 23 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 56 4 Delete the malfunction codes Refer to D 1 DELETING THE MALFUNCTION CODES on page 8 142 5 Perform a trial run Refer to TRIAL RUN on page 4 59 Pocket tester 90890 03112 Analog pocket tester ...

Page 548: ...ELECTRICAL COMPONENTS 8 145 EAS27970 ELECTRICAL COMPONENTS 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 549: ...tor fuse 5 Front brake light switch 6 Clutch switch 7 Fuse box 2 8 Fuse box 1 9 Right radiator fan motor 10 Left radiator fan motor 11 Gear position switch 12 Sidestand switch 13 Oil level switch 14 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse ...

Page 550: ...ELECTRICAL COMPONENTS 8 147 1 17 16 18 19 3 2 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 551: ...nsor 5 ABS motor relay 6 Hydraulic unit 7 ECU engine control unit 8 ABS ECU 9 Cylinder identification sensor 10 O2 sensor 11 Crankshaft position sensor 12 Accessory box solenoid 13 Headlight relay dimmer 14 Radiator fan motor relay 15 Headlight relay on off 16 Brake light relay 17 Turn signal hazard relay 18 Relay unit 19 Lean angle sensor ...

Page 552: ... R Br L Br R ON OFF P Br LBr R R 2 BROWN B B 3 P B Lg Sb Br W L B Ch Dg B Y Y R Y L Y Lg B Sb UP DOWN 13 DgBr W Ch 14 B P 10 12 R Y Y R Y L B 11 B Br W Ch Dg R B R W G Y L W Br 8 L W B R W R B 9 Ch Dg Br W 7 B Y L Y BLACK 6 BLUE B B 5 L B Ch B R Dg B G 4 G Y Br ...

Page 553: ...tch 2 Main switch 3 Rear brake light switch 4 Gear position switch 5 Sidestand switch 6 Clutch switch 7 Hazard switch 8 Start switch 9 Engine stop switch 10 Horn switch 11 Dimmer switch 12 Pass switch 13 Windshield position switch 14 Turn signal switch ...

Page 554: ... 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 posit...

Page 555: ...ition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW3P61001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC3P61002 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 touching t...

Page 556: ...nner panel 1 Refer to GENERAL CHASSIS on page 4 1 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 I...

Page 557: ...ediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC3P61004 This is a sealed battery Never remove 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 M...

Page 558: ...attery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any...

Page 559: ...han 30 minutes Charging method using a constant volt age 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 tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard...

Page 560: ...fication Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R B L W R W R L 1 2 4 3 1 Positive battery terminal 2 Negative b...

Page 561: ...r probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 R Y G L R Y Y W 1 2 3 4 G L Y L B B 1 3 2 G 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive tester probe 2 Negative tester pr...

Page 562: ...al 3 Positive tester probe 4 Negative tester probe Result No 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 ABS motor relay resistance 50 150 Ω Y G G Y Br 1 2 4 3 Br B R Br B R W G Y 1 2 3 4 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red white 1...

Page 563: ...ter DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace NOTE The pocket tester and the analog pocket tester readings are shown in the following table Turn signal hazard relay input voltage DC 12 V Pocket tester 90890 0...

Page 564: ...ace 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 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 black red 3 No continuity P...

Page 565: ...spark plug b Connect the ignition checker 1 as shown c Turn the main switch to ON and engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness Pocket tester 90890 03112 Anal...

Page 566: ...ATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 14 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may bur...

Page 567: ...eter to the spark plug lead of cylinder 1 b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe white 2 Positive tester pr...

Page 568: ...n Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch continuity Out of specification Replace a Connect the pocket tester Ω 1 to the oil level switch terminal as shown Coil resistance 1 01 1 11 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe horn terminal 1 Negative tester probe horn terminal 2 1 2 Oil level switch resistanc...

Page 569: ...tion c Measure the fuel sender resistance EAS28250 CHECKING THE RADIATOR FAN MOTORS The following procedure applies to both of the radiator fan motors 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement Fuel sender Sender unit resistance full 19 0 ...

Page 570: ...asure the coolant temperature sensor re sistance 3 Install Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the th...

Page 571: ... the voltage of white black and black blue Turn the crankshaft twice and check that the output voltage rises to approx imately 4 8 V once EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 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 Solenoid resistance 19 25 Ω at 20 C 68 F Pocke...

Page 572: ...ure that the intake air temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance ET3P61017 CHECKING THE ACCESSORY BOX SOLENOID 1 Check Accessory box solenoid resistance Out of specification Replace a Disconnect the accessory box solenoid cou pler...

Page 573: ...ELECTRICAL COMPONENTS 8 170 c Measure the accessory box solenoid resis tance B Br 1 2 ...

Page 574: ...ELECTRICAL COMPONENTS 8 171 ...

Page 575: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 576: ...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 spark plug cap 4 Ignition coil s Cracked or brok...

Page 577: ...hift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork 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 Wor...

Page 578: ...28610 OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking...

Page 579: ...lty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bu...

Page 580: ...eft radiator fan motor 63 Right radiator fan motor fuse 64 Right radiator fan motor 65 Turn signal hazard relay 66 Auxiliary DC jack 67 Right handlebar switch 68 Front brake light switch 69 Engine stop switch 70 Start switch 71 Hazard switch 72 Left handlebar switch 73 Clutch switch 74 Pass switch 75 Dimmer switch 76 Windshield position switch 77 Turn signal switch 78 Horn switch 79 Relay unit 80 ...

Page 581: ......

Page 582: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 583: ... W Y P W W B B B L BLUE BLUE R Br L B B G R R R Br L B W R L B W R L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L B...

Page 584: ...Br R R Br R G Sb Lg B Sb W Br B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK B B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R...

Page 585: ... A A A B B B A SUB WIRE HARNESS B D GRAY GRAY B GRAY BLACK GREEN GRAY GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS B BLACK GRAY GRAY BLACK GRAY GRAY BROWN BROWN ABS WIRE HARNESS ABS WIRE HARNESS ABS WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 34 34 34 34 35 36 37 38 ...

Page 586: ...belbaum FJR1300A V 2006 SCHEMA ELETTRICO 2 2 Cablaggio elettrico del cupolino FJR1300A V 2006 DIAGRAMA ELÉCTRICO 2 2 Mazo decables delcarenado delantero BLACK BLACK UP DOWN BLACK BLACK BLACK BLACK BLACK GRAY GRAY GRAY GRAY GRAY GRAY 49 31 14 17 52 65 66 67 68 69 71 72 73 74 75 76 77 78 79 70 81 82 83 84 85 86 87 88 89 80 91 92 93 94 95 96 96 97 98 99 90 101 101 102 102 103 104 105 100 ...

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