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Yamaha 2006 YZFR6V, Service Manual

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Yamaha 2006 YZFR6V Service Manual Download Page 87

CABLE ROUTING

2-56

1. Throttle cable (decelerator cable)
2. Throttle cable (accelerator cable)
3. Front brake hose
A. Pass the throttle cables between the front fork and

the front brake hose.

B. When installing the guide on the lower bracket, be

sure to pass the front brake hose through it.

C. Fasten the front brake hose with the holder,

making sure that the paint mark on the hose is
visible through the hole in the holder.

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Summary of Contents for 2006 YZFR6V

Page 1: ...2006 SERVICE MANUAL YZF R6 V 2C0 28197 E0 ...

Page 2: ...R6 V 2006 SERVICE MANUAL 2005 by Yamaha Motor Co Ltd First edition November 2005 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: ... page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruc...

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

Page 6: ......

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: ...YSTEM 1 3 YCC T Yamaha Chip Controlled Throttle 1 4 INSTRUMENT FUNCTIONS 1 7 IMPORTANT INFORMATION 1 12 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 12 REPLACEMENT PARTS 1 12 GASKETS OIL SEALS AND O RINGS 1 12 LOCK WASHERS PLATES AND COTTER PINS 1 12 BEARINGS AND OIL SEALS 1 13 CIRCLIPS 1 13 CHECKING THE CONNECTIONS 1 14 SPECIAL TOOLS 1 15 ...

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

Page 11: ... 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 the engine ope...

Page 12: ...hrottle valves coolant temperature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor air temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that...

Page 13: ... made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability Air intake volume is controlled according to the opera...

Page 14: ...l unit 5 ETV main CPU 32 bit 6 ETV sub CPU 16 bit 7 FI CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sensing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 18 A...

Page 15: ...sensor 5 Coolant temperature sensor 6 Neutral switch 7 Atmospheric pressure sensor 8 Throttle position for throttle cable pulley two signals 9 Throttle position for throttle valves two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map 18 Idle speed control 19 Calculated thro...

Page 16: ...rol mode NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the speedometer and odometer tripmeter displays between kilo meters and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachom...

Page 17: ...he display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SELECT button The stopwatch digits will start flashing Release the SELECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stop watch 2 P...

Page 18: ...equipped with a self diagno sis device for the immobilizer system If any of the immobilizer system circuits are de fective the immobilizer system indicator light will flash and then the odometer trip meter fuel re serve trip meter stopwatch display will indicate a two digit error code e g 51 52 53 NOTE If the display indicates error code 52 this could be caused by transponder interference If this ...

Page 19: ...or light stays on The indicator light will flash when activated This setting is selected when the indicator light flashes four times per second The indicator light is deactivated in other words it will not come on or flash This set ting is selected when the indicator light flash es once every two seconds 2 Push the SELECT button to confirm the se lected indicator light activity The control mode ch...

Page 20: ...icator light bright ness 1 Push the RESET button to select the de sired indicator light brightness level 2 Push the SELECT button to confirm the se lected indicator light brightness level The dis play will return to the odometer or tripmeter mode ...

Page 21: ... 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 22: ...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 23: ...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 24: ...t provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 14 5 35 8 93 8 94 8 95 8 99 8 100 8 101 8 102 8 103 8 104 8 105 8 106 8 107 8 108 8 109 8 110 Valve lapper 90890 04101 Valve lapping tool ...

Page 25: ...g nut wrench 90890 01403 Spanner wrench YU 33975 3 27 4 57 Fork spring compressor 90890 01441 YM 01441 4 47 4 52 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 47 4 52 Damper rod holder 90890 01506 4 48 4 49 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 50 Tool name Tool No Illustration Reference pages ...

Page 26: ...01436 Universal damping rod bleeding tool set YM A8703 4 50 4 52 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 57 Ring nut wrench 90890 01507 4 66 4 68 Damper rod holder 24 mm 90890 01328 YM 01328 4 66 4 67 Valve spring compressor 90890 04019 YM 04019 5 19 5 24 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 ...

Page 27: ...r ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 21 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 21 Valve spring compressor 90890 04109 5 24 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 28 5 29 5 31 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 28 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 29 5 31 5 57 Tool name Tool No Illus...

Page 28: ...pin puller set 90890 01304 Piston pin puller YU 01304 5 60 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Tool name Tool No Illustration Reference pages 0 40 0 30 0 35 0 25 0 20 0 15 0 10 0 05 0 03 0 50 YU 01304 YU 24460 01 YU 33984 ...

Page 29: ... 03153 7 10 Fuel pressure adapter 90890 03176 YM 03176 7 10 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 11 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 102 Tool name Tool No Illustration Reference pages ...

Page 30: ...SPECIAL TOOLS 1 21 ...

Page 31: ...TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 21 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 43 CABLE ROUTING 2 47 ...

Page 32: ...04 AUS Dimensions Overall length 2040 mm 80 3 in Overall width 700 mm 27 6 in Overall height 1100 mm 43 3 in Seat height 850 mm 33 5 in Wheelbase 1380 mm 54 3 in Ground clearance 130 mm 5 12 in Minimum turning radius 3600 mm 141 7 in Weight With oil and fuel 182 0 kg 401 lb Maximum load 193 kg 425 lb ...

Page 33: ...antity Total amount 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 40 L 2 54 US qt 2 11 Imp qt With oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Oil cooler capacity including all routes 0 23 L 2 43 US qt 2 02 Imp qt Oil pressure hot 80 0 kPa 1300 r min 11 6 psi 1300 r min 0 80 kgf cm 1300 r min Oil filter Oil filter type Cartridge paper Oil pump Oil pump...

Page 34: ...l pump Reduction ratio 85 41 29 31 1 939 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CR10EK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Volume 7 40 8 20 cm 0 45 0 50 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 22 500 22 521 mm 0 8858 0 8867 in Camshaft journal diameter 22 459 22 472 mm 0 88...

Page 35: ...9 mm 0 0047 0 0075 in Exhaust 0 16 0 23 mm 0 0063 0 0091 in Valve dimensions Valve head diameter A intake 26 90 27 10 mm 1 0591 1 0669 in Valve head diameter A exhaust 22 90 23 10 mm 0 9016 0 9094 in Valve face width B intake 1 410 2 550 mm 0 0555 0 1004 in Valve face width B exhaust 1 400 2 670 mm 0 0551 0 1051 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve ...

Page 36: ... 0 052 mm 0 0010 0 0020 in Limit 0 095 mm 0 0037 in Valve stem runout 0 040 mm 0 0016 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in Valve spring Free length intake 37 47 mm 1 48 in Limit 35 60 mm 1 40 in Free length exhaust 37 67 mm 1 48 in Limit 35 79 mm 1 42 in ...

Page 37: ... 66 975 66 990 mm 2 6368 2 6374 in Height H 10 0 mm 0 39 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043 mm 0 5922 in Piston pin outside diameter 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 00007 0 00068 in Piston ring Top ring Ring type B...

Page 38: ...0 48 25 mm 1 898 1 900 in Cylinders 3 and 4 47 90 47 95 mm 1 886 1 888 in Width B 268 80 270 00 mm 10 58 10 63 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Small end free play F 0 32 0 50 mm 0 01 0 02 in Journal oil clearance using plastigauge 0 020 0 044 mm 0 0008 0 0017 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Clutch Clutch ty...

Page 39: ...in axle runout limit 0 02 mm 0 0008 in Drive axle runout limit 0 02 mm 0 0008 in Shifting mechanism Shift mechanism type Shift drum Shift fork guide bar bending limit 0 050 mm 0 0020 in Shift fork thickness 5 760 5 890 mm 0 2268 0 2319 in Shift fork thickness 5 795 5 868 mm 0 2281 0 2310 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 2C0...

Page 40: ... V Intake air pressure sensor output voltage 3 15 4 15 V Atmospheric pressure sensor output voltage 3 15 4 15 V Idling condition Engine idling speed 1250 1350 r min Intake vacuum 20 0 kPa 5 9 inHg 150 mmHg Water temperature 95 0 105 0 C 203 00 221 00 F Oil temperature 82 92 C 180 198 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in Air induction system Reed valve bending limit 0 4 mm 0 016 in So...

Page 41: ...2 in Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D209F PT Manufacturer model MICHELIN Pilot POWER P Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model DUNLOP D209PT Manufacturer model MICHELIN Pilot POWER 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 250...

Page 42: ... inner 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 18 mm 1 50 in Recommended fluid DOT 4 Steering Steering head tension 200 500 g Steering bearing type Angular bearing Lock to lock angle left 25 0 Lock to lock angle right 25 0 Front suspension Type Telesc...

Page 43: ... 98 00 N mm 559 58 lb in 9 99 kgf mm Spring stroke K1 0 0 60 0 mm 0 00 2 36 in Optional spring available No Enclosed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive chain Type manufacturer 525V8 DAIDO Link quantity 114 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 15 link length li...

Page 44: ...oil resistance 8 5 11 5 kΩ AC magneto Model manufacturer LMX62 DENSO Standard output 14 0 V 420 W 5000 r min Stator coil resistance 0 12 0 18 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH678 11 SHINDENGEN Regulated voltage DC 14 1 14 9 V Rectifier capacity 22 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Manufacturer GS YUASA Ten hour ...

Page 45: ...m 0 39 in Limit 3 50 mm 0 14 in Brush spring force 7 16 9 52 N 25 77 34 27 oz 730 971 gf Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768109 A JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω at 20 C 68 F Performance 105 113 ...

Page 46: ...urer G8R 30Y V4 OMRON Fan motor relay Model manufacturer ACM33211M05 MATSUSHITA Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 7 5 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Fuel injection system fuse 15 0 A Backup fuse 7 5 A Electric throttle valve fuse 7 5 A Reserve fuse 15 0 A Reserve fuse 10 0 A Reserve fuse 7 5 A Reserve fuse 15 0 A ...

Page 47: ...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 48: ...tle body joint bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Connecting rod nut 1st M7 8 15 Nm 1 5 m kg 11 ft lb See NOTE Connecting rod nut final M7 8 Specified angle 175 185 See NOTE Generator rotor bolt M12 1 70 Nm 7 0 m kg 50 ft lb Timing chain tensioner bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Water pump ...

Page 49: ...2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt front side M6 1 8 Nm 0 8 m kg 5 8 ft lb EXUP valve pulley cover bolt rear side M6 2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve nut M6 1 7 Nm 0 7 m kg 5 1 ft lb Crankcase bolt M8 2 See NOTE l 115mm 4 53 in Crankcase bolt M8 8 See NOTE l 85 mm 3 35 in Crankcase bolt M8 2 24 Nm 2 4 m kg 17 ft lb l 65 mm 2 56 in Crankcase bolt M6 15 10 Nm 1 0 m kg 7 2 ft ...

Page 50: ... 8 7 ft lb Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Crankcase stud bolt M10 10 See NOTE Pressure plate bolt M6 6 8 Nm 0 8 m kg 5 8 ft lb Clutch boss nut M20 1 115 Nm 11 5 m kg 85 ft lb Stake Clutch boss plate stud bolt M8 6 25 Nm 2 5 m kg 18 ft lb Drive sprocket nut M20 1 85 Nm 8 5 m kg 61 ft lb Stake Main axle screw M6 3 12 Nm 1 2 m kg 8 7 ft lb Stake Shift drum retainer bolt...

Page 51: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence Crankcase tightening sequence 8 6 2 4 10 9 3 1 5 7 12 11 2 6 9 8 1 4 3 5 7 10 13 25 26 14 20 12 21 11 15 19 18 16 28 27 17 24 23 22 ...

Page 52: ...w front and rear M8 3 5 Nm 0 5 m kg 3 6 ft lb Front brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brake caliper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Rear brake caliper bolt M12 1 27 Nm 2 7 m kg 19 ft lb Rear brake pad pin M10 1 17 Nm 1 7 m kg 12 ft lb Rear brake screw plug 1 2 Nm 0 2 m kg 1 4 ft lb Handlebar pinch bolt M8 2 32 Nm 3 2...

Page 53: ... Rear shock absorber assembly upper nut M12 1 44 Nm 4 4 m kg 32 ft lb Rear shock absorber assembly lower nut M12 1 40 Nm 4 0 m kg 29 ft lb Rear shock absorber assembly spacer bolt M22 1 16 Nm 1 6 m kg 11 ft lb Rear shock absorber assembly bracket nut M14 1 52 Nm 5 2 m kg 37 ft lb Swingarm pivot shaft M32 1 16 Nm 1 6 m kg 11 ft lb Swingarm pivot shaft ring nut M32 1 95 Nm 9 5 m kg 68 ft lb Swingarm...

Page 54: ...lder bolt M6 2 5 Nm 0 5 m kg 3 6 ft lb Radiator bracket and radiator bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator bracket and frame bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator outlet hose holder bolt M10 1 13 Nm 1 3 m kg 9 4 ft lb Coolant reservoir bolt M6 2 5 Nm 0 5 m kg 3 6 ft lb Front cowling assembly bolt M6 4 13 Nm 1 3 m kg 9 4 ft lb Seat lock plate bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rider seat...

Page 55: ...Nm 5 2 m kg 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 14 Nm 1 4 m kg 10 ft lb with a torque wrench NOTE Lower bracket pinch bolt Tighten each bolt to 23 Nm 2 3 m kg 17 ft lb in the order pinch bolt 1 pinch bolt 2 pinch bolt 1 4 1 3 2 1 2 ...

Page 56: ... inner and outer and oil pump housing Oil strainer screen inside oil strainer Oil strainer gasket Oil nozzle O ring Starter clutch idle gear shaft Starter clutch roller and starter clutch idle gear outer surface Primary driven gear inner surface Clutch pull rod Transmission gears wheel and pinion and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Cylinder head c...

Page 57: ...ATION POINTS AND LUBRICANT TYPES 2 26 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 58: ...Swingarm dust cover lips Swingarm pivot shaft nut Oil seals rear shock absorber relay arm and connecting arm Seat lock lever pivoting point Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Sidestand bracket and sidestand bolt Shift rod pivoting point Shift pedal pivoting point Brake pedal shaft pivoting p...

Page 59: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 6 5 4 3 2 1 11 12 13 14 10 9 7 8 ...

Page 61: ...ND DIAGRAMS 2 30 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil filter 5 Oil cooler 6 Main gallery 7 Oil nozzle 8 Timing chain tensioner 9 Intake camshaft 10 Exhaust camshaft 11 Oil pipe 12 Main axle 13 Shift fork 14 Drive axle ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Ventilation chamber cover 2 Relief valve 3 Ventilation chamber oil drain pipe 4 Oil cooler ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2 3 4 8 7 6 5 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Oil check bolt 5 Oil strainer 6 Ventilation chamber oil drain pipe 7 Oil pipe 8 Oil pump ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 2 3 4 5 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil cooler 2 Oil filter 3 Oil pipe 4 Oil pump 5 Oil strainer ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 5 4 3 2 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Oil pump 3 Oil pipe 4 Ventilation chamber oil drain pipe 5 Relief valve ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 3 1 2 5 4 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil nozzle ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 1 3 2 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil pipe 2 Main axle 3 Drive axle ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 43 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 ...

Page 75: ...COOLING SYSTEM DIAGRAMS 2 44 1 Radiator inlet hose 2 Radiator inlet pipe 3 Thermostat outlet hose 4 Radiator ...

Page 76: ...COOLING SYSTEM DIAGRAMS 2 45 A A 2 1 3 4 5 6 7 8 6 13 8 9 15 14 9 10 11 12 ...

Page 77: ... Coolant reservoir 4 Radiator 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Radiator outlet pipe 8 Water jacket joint inlet hose 9 Water pump outlet pipe 10 Water pump inlet hose 11 Water pump outlet hose 12 Water pump 13 Water jacket joint 14 Oil cooler 15 Oil cooler inlet hose ...

Page 78: ...CABLE ROUTING 2 47 EAS20430 CABLE ROUTING A A A B C D E F G H I J 1 2 3 4 5 6 7 8 9 9 10 11 11 12 12 14 15 16 17 18 19 13 ...

Page 79: ...g tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie to 2 10 mm 0 08 0 39 in B Be sure to position the plastic locking tie above where the horn leads branch off from the other leads C 40 50 mm 1 57 1 97 in D Pass the throttle cables through the guide on the lower bracket making sure to route the decelerator cable above the accelerator cable as shown in t...

Page 80: ...CABLE ROUTING 2 49 1 2 3 3 4 4 4 5 5 6 7 8 9 10 11 12 13 14 14 15 15 16 15 16 17 18 19 19 20 20 21 21 22 23 24 25 26 27 A B P C D E F G H I K J L M N O 60 A A B B D D C A A B B D D C Q ...

Page 81: ...her hose and clutch cable and then fasten them with the holder making sure to align the top of the holder with the bottom edge of the white paint mark on the cable G Fasten the clutch cable to the radiator outlet hose with the plastic band making sure to position the band between the screw clamp and the hose protector Install the plastic band with its buckle positioned toward the rear of the vehic...

Page 82: ...CABLE ROUTING 2 51 C C B B B C C A A B B A C N O D H I J K L M 1 2 2 3 4 5 6 7 7 8 8 9 11 12 13 14 10 9 15 7 8 14 15 E F G ...

Page 83: ...ank drain hose and fuel tank breather hose with the holder making sure to fasten the hoses below the holder on the engine G 30 50 mm 1 18 1 97 in H Pass the fuel tank drain hose fuel tank breather hose and sidestand switch lead through the guides on the sidestand shield making sure to route the lead to the inside of the hoses I Pass the AC magneto lead between the frame and the throttle body and t...

Page 84: ...ING 2 53 B B B C C A A B A B C D E F G H I J K L M N O E P E Q R Y Z X S W V U T T 1 2 3 4 5 7 6 7 6 8 8 9 10 10 11 11 12 13 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 33 45 135 A A C C ...

Page 85: ... around the wire harness into the hole in the frame L Pass the neutral switch lead between the frame and the engine M To the ECU N Install both the engine ground lead terminal and the negative battery lead terminal to the crankcase with the bolt Make sure that the oil level switch lead and speed sensor lead are routed under the engine ground lead and negative battery lead the leads are positioned ...

Page 86: ...CABLE ROUTING 2 55 A 3 1 2 3 C B ...

Page 87: ...se A Pass the throttle cables between the front fork and the front brake hose B When installing the guide on the lower bracket be sure to pass the front brake hose through it C Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder ...

Page 88: ...CABLE ROUTING 2 57 1 2 4 5 6 7 8 9 10 11 12 12 3 A C E B D 2 3 7 8 9 12 ...

Page 89: ...el rail 8 Intake air pressure sensor lead 9 Sub wire harness 3 10 Atmospheric pressure sensor lead 11 Sub wire harness 2 12 Intake air pressure sensor hose A Face the ends of the clamp rearward B Route the sub wire harness 3 to the left side of the intake air pressure sensor C Fasten the atmospheric pressure sensor lead with the holder on the air filter case D Route the atmospheric pressure sensor...

Page 90: ...LE ROUTING 2 59 F F C C E E D D A A G G B B A B C D E G H F I J K L M 1 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 13 17 1 2 2 3 3 6 7 8 7 8 10 11 14 15 16 18 N 1 15 18 14 11 16 A A B B C C D D E E F F G G ...

Page 91: ...heft alarm couplers OPTION between the ECU and the rear lower cowling F Do not route the turn signal hazard relay lead or relay unit lead over the front of the battery box or the damper G Pass the negative battery lead between the battery band and the battery H Pass the plastic band through the hole in the rib on the rear lower cowling from the front and then fasten the turn signal light couplers ...

Page 92: ...CABLE ROUTING 2 61 ...

Page 93: ...6 CHECKING THE COOLANT LEVEL 3 17 CHECKING THE COOLING SYSTEM 3 18 CHANGING THE COOLANT 3 19 CHASSIS 3 21 ADJUSTING THE FRONT DISC BRAKE 3 21 ADJUSTING THE REAR DISC BRAKE 3 21 CHECKING THE BRAKE FLUID LEVEL 3 22 CHECKING THE FRONT BRAKE PADS 3 22 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSES 3 23 CHECKING THE REAR BRAKE HOSES 3 23 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 23 BLEE...

Page 94: ...ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 REPLACING THE HEADLIGHT BULBS 3 35 ADJUSTING THE HEADLIGHT BEAMS 3 35 ...

Page 95: ......

Page 96: ... Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limi...

Page 97: ...leakage 20 Rear suspension re lay arm and connect ing arm pivoting points Check operation 21 Fuel injection system Adjust synchronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts a...

Page 98: ...cut off valve Refer to AIR INDUCTION SYSTEM on page 7 13 Radiator Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Refer to CAMSHAFTS on page 5 7 3 Remove Pickup rotor cover 1 4 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 th...

Page 99: ...er the timing chain opening with a rag to prevent the valve pad from falling into the 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 11 0 20 mm 0 004 0 008 in Measured valve clearance...

Page 100: ...lve lifter with engine oil The valve lifter must turn smoothly when rotat ed by hand Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts tim ing chain and camshaft caps NOTE Refer to CAMSHAFTS on page 5 7 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the ca...

Page 101: ...c Using the throttle body that has the bypass air screw with a white paint mark as the stan dard turn the bypass air screws without white paint marks in or out to the adjust the other throttle bodies NOTE If more than one throttle body has a bypass air screw with a white paint mark use the one with the lowest vacuum pressure as the standard After each step rev the engine two or three times each ti...

Page 102: ... speed does not rise abnormally high 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 10 Install Caps Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20600 ADJUSTING THE EXHAUST GAS VOLUME NOTE Be sure to set the CO density level to standard and then adjust the exhaust gas volume 1 Turn the main switch to OFF...

Page 103: ...e lection step 5 10 Turn the main switch to OFF to cancel the CO adjustment mode EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchroniza tion should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play a Loosen the locknut 1 b Turn the adj...

Page 104: ...id Refer to AIR INDUCTION SYSTEM on page 7 13 Air filter case Refer to AIR FILTER CASE on page 7 4 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of sp...

Page 105: ...0 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Dipstick 1 4 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommende...

Page 106: ...it up for several min utes and then turn it off 2 Remove Left lower side cowling Left bottom cowling Refer to GENERAL CHASSIS on page 4 1 3 Place a container under the engine oil drain bolt 4 Remove Engine oil filler cap 1 5 Remove Engine oil drain bolt 1 along with the gasket 6 Drain Engine oil completely from the crankcase 7 If the oil filter cartridge is also to be replaced perform the followin...

Page 107: ...Engine oil drain bolt gasket Damage Replace 9 Install Engine oil drain bolt along with the gasket 10 Fill Crankcase with the specified amount of the recom mended engine oil 11 Install Engine oil filler cap 12 Start the engine warm it up for several min utes and then turn it off 13 Check Engine for engine oil leaks 14 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 10 Oil fi...

Page 108: ...gauge set 1 Oil pressure adapter H 2 6 Measure Engine oil pressure at the following conditions Out of specification Adjust 7 Install Main gallery bolt 8 Install Left bottom cowling Left lower side cowling Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust Oil pressure gauge set 90890 03120 Oil pressure ada...

Page 109: ... 2400 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element CAUTION EC2C01007 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 affect the throttle body synchr...

Page 110: ...ies to all of the fuel vacuum and breather hoses 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Fuel hoses 1 Vacuum hoses Overflow hose 2 Breather hose 3 Cracks damage Replace Loose connection Connect properly CAUTION ECA14940 Make sure the fuel tank breather hose is rout ed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Ride...

Page 111: ...footrest bracket bolt 7 4 Install Bottom cowlings Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation a Activate the diagnostic mode and select the diagnostic code number 53 Refer to FUEL INJECTION SYSTEM on page 8 33 b Set the engine stop switch to c Check that the EXUP valve operates proper ly T R ...

Page 112: ...P valve pulley cover EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright EXUP cable free play at the EXUP valve pulley 1 5 mm 0 06 in or less Direction a Free play is increased Direction b Free play is decreased EXUP cable free play at the EXUP valve pulley c 1 5 mm 0 06 in or less b a a T R Locknut ...

Page 113: ...eral min utes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 2 Check Radiator 1 Radiator inlet hose 2 Radiator inlet pipe 3 Thermostat outlet hose 4 Radiator ...

Page 114: ...copper washer 4 Disconnect Water pump inlet hose 2 5 Drain Coolant from the engine and radiator 6 Remove Coolant reservoir 1 Coolant reservoir cap 2 7 Drain Coolant from the coolant reservoir 8 Install Coolant reservoir 9 Connect Water pump inlet hose 10 Install Coolant drain bolt water pump along with the copper washer 11 Fill Cooling system with the specified amount of the recom mended coolant H...

Page 115: ...le 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 several min utes and then stop it 16 Check Coolant level Refer to CHECK...

Page 116: ... DISC BRAKE 1 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 check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification WARNING EW2C01004 A soft or spongy feeling in the brake pedal ...

Page 117: ...rmful 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 immediately NOTE In order to ensure a correct ...

Page 118: ...holders 2 Loose connection Connect 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 29 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on jus...

Page 119: ... reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 NOTE The bleeding order of the front hydraulic brake system is the following 1 Front brake master cylinder 2 Front brake calipers 3 Front brake master cylinder d Place the other end of the hose into a con tainer e Slowly apply t...

Page 120: ... page 4 1 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no d...

Page 121: ...in solvents and the use of a coarse brush can damage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEERING...

Page 122: ...er washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 54 6 Measure Steering...

Page 123: ...G EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube 1 Damage scratches Replace Oil seal 2 Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 44 EAS21580...

Page 124: ... suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 0 Standard 1 Maximum 5 2 Current setting 3 Cap bolt collar 1 a b Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Stan...

Page 125: ...ion a or b c Align the desired position on the adjusting ring with the position indicator 2 Compression damping adjusting positions fast compression damp ing Minimum Distance c 8 mm 0 31 in Standard Distance c 10 mm 0 39 in Maximum Distance c 12 mm 0 47 in Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is s...

Page 126: ...imum 9 Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 20 click s out Standard 10 click s out Maximum 3 click s out With the adjusting screw fully turned in 1 a b 2 Direction a turn in Compression damping is increased suspension is harder Direction b turn out ...

Page 127: ...hen the tire tread reaches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer Compression damping adjusting positions slow compression damping Minimum 24 click s out Standard 15 click s out Maximum 1 click ...

Page 128: ...ng handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tir...

Page 129: ...f lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to metal moving parts of the pedals EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand E...

Page 130: ...d down 5 Install Headlight 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 ...

Page 131: ... horizontally a Turn the adjusting screw 1 in direction a or b A Left headlight B Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right A Left headlight B Right headlight a 1 B b 1 a A b a b 1 B ...

Page 132: ...ELECTRICAL SYSTEM 3 37 ...

Page 133: ... AND REPLACING THE REAR WHEEL SPROCKET 4 14 ASSEMBLING THE REAR WHEEL 4 15 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 15 CHECKING THE REAR BRAKE DISC 4 15 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 15 FRONT BRAKE 4 17 INTRODUCTION 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE PADS 4 23 REMOVING THE FRONT BRAKE CALIPERS 4 24 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 24 CHECKING ...

Page 134: ...ING THE HANDLEBARS 4 42 FRONT FORK 4 44 REMOVING THE FRONT FORK LEGS 4 47 DISASSEMBLING THE FRONT FORK LEGS 4 47 CHECKING THE FRONT FORK LEGS 4 48 ASSEMBLING THE FRONT FORK LEGS 4 49 INSTALLING THE FRONT FORK LEGS 4 52 STEERING HEAD 4 54 REMOVING THE LOWER BRACKET 4 57 CHECKING THE STEERING HEAD 4 57 INSTALLING THE STEERING HEAD 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 59 HANDLING THE REAR SHOCK ABSORB...

Page 135: ...IVE 4 69 REMOVING THE DRIVE CHAIN 4 70 CHECKING THE DRIVE CHAIN 4 70 CHECKING THE DRIVE SPROCKET 4 71 CHECKING THE REAR WHEEL SPROCKET 4 71 CHECKING THE REAR WHEEL DRIVE HUB 4 71 INSTALLING THE DRIVE CHAIN 4 71 ...

Page 136: ...ent cover if the vehicle is registered for only a solo rider 3 Passenger seat replacement cover 1 Installed for solo riding only 4 Fuel tank bracket 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery band 1 8 Battery 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 1 8 7 5 6 4 2 ...

Page 137: ...tor 2 Disconnect 6 License plate light assembly 1 7 Rear upper cowling damper plate 1 8 Tail brake light coupler 1 Disconnect 9 Tail brake light assembly 1 10 Right passenger footrest 1 CAUTION EC2C01026 Install the cowling hole cover if the vehi cle is registered for only a solo rider 11 Left passenger footrest 1 CAUTION EC2C01026 Install the cowling hole cover if the vehi cle is registered for o...

Page 138: ...er 1 Installed for solo riding only 14 Rear lower cowling 1 For installation reverse the removal proce dure Removing the tail brake light assembly Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib 2 12 13 8 14 1 10 6 9 4 3 5 7 11 4 4 ...

Page 139: ...l light coupler 2 Disconnect 5 Bottom cowling 2 6 Bottom cowling inner panel 2 7 Air intake duct 2 8 Rearview mirror 2 9 Headlight sub wire harness 1 coupler 1 Disconnect 10 Headlight sub wire harness 2 coupler 1 Disconnect 11 Front cowling assembly 1 For installation reverse the removal proce dure 5 4 5 4 7 3 R 13 Nm 1 3 m kg 9 4 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 6 7 2 1 6 3 8 11 10 9 4 8 1 2 ...

Page 140: ... so that the front wheel is elevated 1 Left front brake hose holder 1 2 Right front brake hose holder 1 3 Left front brake caliper 1 4 Right front brake caliper 1 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Collar 2 10 Dust cover 2 11 Front brake disc 2 For installation reverse the removal proce dure ...

Page 141: ...FRONT WHEEL 4 6 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 142: ...ver 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 Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIR...

Page 143: ...heel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the...

Page 144: ...o CHECKING THE FRONT BRAKE DISCS on page 4 22 EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 3 Lubricate Oil seal lips 4 Install Front wheel NOTE Install th...

Page 145: ...ht end of the front wheel axle is flush with the front fork If necessary manually push the front wheel axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front wheel axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the f...

Page 146: ...n a suitable stand so that the rear wheel is elevated 1 Rear brake caliper 1 2 Drive chain adjusting locknut 2 Loosen 3 Drive chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Rear wheel 1 8 Brake pad spring 1 9 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 147: ...et Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 1 4 Dust cover 1 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Dust cover 1 10 Collar 1 For installation reverse the removal proce dure ...

Page 148: ...REAR WHEEL 4 13 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 149: ...WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 7 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 7 ET2C01024 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake ...

Page 150: ... rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 8 ET2C01004 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 34 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a c...

Page 151: ...CHAIN SLACK on page 3 25 5 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Drive chain slack 35 0 45 0 mm 1 38 1 77 in T R Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE ...

Page 152: ...r Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Front brake pad 2 For installation reverse the removal proce dure ...

Page 153: ...Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch connector 2 Disconnect 9 Front brake light switch 1 10 Front brake hose union bolt 1 11 Copper washer 2 12 Front brake hose 1 13 Front brake master cylinder holder 1 14 Front brake master cylinder 1 For installation reverse the removal proce dure LS T R 13 Nm 1 3 m ...

Page 154: ...ront brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure LS 1 3 2 1 T R 6 Nm 0 6 m kg 4 3 ft Ib New New ...

Page 155: ...owing procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Brake hose holder 1 2 Front brake hose union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 156: ...ve Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 157: ...ISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 5 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 t...

Page 158: ...e pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring NOTE The arrow mark a on the brake pad spring must point in the dire...

Page 159: ...re applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW2C01005 Do not loosen the bolts 3 a Blow compressed air into the brake hose joint opening a to force out the left side pistons from the brake caliper WARNING EWA13580 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake mast...

Page 160: ...ake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 47 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remov...

Page 161: ...4 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hoses 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1...

Page 162: ...ir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling ...

Page 163: ...FRONT BRAKE 4 28 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 a ...

Page 164: ... the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 2 5 Brake pad insulator 2 6 Rear brake pad 2 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 165: ...id reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure New New T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2...

Page 166: ...bling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure New New New LS 2 1 3 ...

Page 167: ...ts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 5 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 168: ... Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad shim 2 4 Brake pad insulator 2 5 Rear brake pad 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston seal 2 9 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 169: ...amage 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 22 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 22 5 Adjust Brake disc deflection Refer...

Page 170: ...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 on page 3 24 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper...

Page 171: ...ke fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new ...

Page 172: ... the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic pa...

Page 173: ...amage Replace 4 Check Rear brake hose Brake fluid reservoir hose Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Rear brake hose ...

Page 174: ...por lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 5 Check Brake p...

Page 175: ...utch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 Disconnect 6 Clutch lever assembly 1 7 Right grip end 1 8 Throttle cable housing 2 9 Throttle cable 2 Disconnect 10 Throttle grip 1 11 Front brake light switch connector 2 Disconnect T R 32 Nm 3 2 m kg 23 ft Ib LS T R 115 Nm 11 5 m kg 85 ft lb T R 13 Nm 1 3 m kg 9 4 ft Ib LS T R 26 Nm 2 6 m kg 19 ft Ib T R 5 Nm 0 5 m kg ...

Page 176: ...1 Disconnect 22 Upper bracket 1 23 Handlebar pinch bolt 2 Loosen 24 Left handlebar 1 25 Right handlebar 1 For installation reverse the removal proce dure Removing the handlebars Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib LS T R 115 Nm 11 5 m kg 85 ft lb T R 13 Nm 1 3 m kg 9 4 ft Ib LS T R 26 Nm 2 6 m kg 19 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 11...

Page 177: ...curely support the vehicle so that there is no danger of it falling over 2 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Install the brake master cylinder holder with the UP mark a facing up Align the mating surfaces of the brake master cylinder holder with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 3 Install Right handlebar...

Page 178: ... any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 9 Check Cable routing NOTE Make sure the immobilizer unit lead main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed pro...

Page 179: ...RONT WHEEL on page 4 5 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T ...

Page 180: ...egs 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Damper adjusting rod 1 5 Nut 1 6 Spacer 1 7 Fork spring 1 8 Spring seat 1 9 Outer tube 1 10 Dust seal 1 11 Oil seal clip 1 12 Oil seal 1 13 Washer 1 14 Damper rod assembly 1 T R 25 Nm 2 5 m kg 18 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 1 2 New 3 5 6 7 8 9 13 12 11 10 New New New 4 14 15 ...

Page 181: ...y reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks T R 25 Nm 2 5 m kg 18 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 1 2 New 3 5 6 7 8 9 13 12 11 10 New New New 4 14 15 ...

Page 182: ... THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Position the collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spac...

Page 183: ...ip 1 with a flat head screwdriver EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruc...

Page 184: ...lace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tight...

Page 185: ...al clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A...

Page 186: ... and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Spring seat 1 Fork spring 2 Spacer 3 Nut 4 Damper adjusting rod 5 Washer 6 Cap bolt 7 with O ring a Remove the rod puller attachm...

Page 187: ...move the rod holder and fork spring com pressor 16 Install Cap bolt to the outer 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 WARNING EWA13680 Make sure the brake hoses are routed prop erly NOTE Make sure the outer...

Page 188: ...n page 2 47 5 Install Plastic locking tie 1 Plastic locking tie 2 NOTE Fasten the left handlebar switch lead to the left front fork leg with the plastic locking tie Fasten the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 28 T R Cap bolt 20 Nm 2 0 m kg 14 ft lb T...

Page 189: ...tifier regulator holder 1 2 Left coupler holder 1 3 Main switch coupler 2 Disconnect 4 Immobilizer unit coupler 1 Disconnect 5 Clutch cable 1 Disconnect 6 Left handlebar assembly 1 7 Right handlebar assembly 1 8 Horn connector 2 Disconnect 9 Horn 1 10 Front brake hose joint 1 7 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 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T ...

Page 190: ...g 1 23 Lower bearing 1 24 Lower bearing inner race 1 25 Lower bearing dust seal 1 26 Upper bearing outer race 1 Removing the lower bracket Order Job Parts to remove Q ty Remarks 7 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 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 14 Nm 1 4 m kg 10 ft Ib T R 115 Nm 11 5 m kg 85 ft lb T R 5 Nm 0 ...

Page 191: ...rts to remove Q ty Remarks 7 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 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 14 Nm 1 4 m kg 10 ft Ib T R 115 Nm 11 5 m kg 85 ft lb T R 5 Nm 0 5 m kg 3 6 ft Ib LS 13 14 15 16 17 1 3 4 2 8 21 18 5 9 19 11 10 12 6 20 22 26 27 23 24 25 ...

Page 192: ...eplace 3 Replace Bearings Bearing races a Remove the bearing race 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...

Page 193: ...em nut 6 Install Front brake hose joint bracket 1 Lower bracket cover 2 Front brake hose joint 3 NOTE Make sure that the tab a on the front brake hose joint bracket contacts the side b of the front brake hose joint 7 Check Cable routing NOTE Make sure the immobilizer unit lead main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE RO...

Page 194: ...bsorber assembly lower nut Wash er Bolt 1 1 1 4 Rear shock absorber assembly bracket nut 1 5 Rear shock absorber assembly upper nut Bolt 1 1 6 Rear shock absorber assembly bracket 1 7 Rear shock absorber assembly 1 8 Spacer bolt 1 9 Relay arm nut Bolt Spacer 1 1 1 10 Relay arm 1 11 Spacer 1 12 Spacer 1 1 1 1 1 2 9 13 15 14 13 12 15 10 9 9 3 5 13 8 4 6 7 14 13 11 3 5 2 1 1 LS LS LS LS LS New New Ne...

Page 195: ...r shock absorber assembly Order Job Parts to remove Q ty Remarks 1 1 1 1 2 9 13 15 14 13 12 15 10 9 9 3 5 13 8 4 6 7 14 13 11 3 5 2 1 1 LS LS LS LS LS New New New New 13 3 T R 16 Nm 1 6 m kg 11 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 52 Nm 5 2 m kg 37 ft Ib T R 44 Nm 4 4 m kg 32 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib ...

Page 196: ...hole through the rear shock absorber at a point 50 mm 1 97 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...

Page 197: ... EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacer 2 Tighten Relay arm nut 3 Install Spacer bolt Rear shock absorber assembly Rear shock absorber assembly bracket 1 NOTE Be sure to fit the projection on either side of the rear shock absorber assembly bracket into the indentation in the frame Recommended lubricant Lithium soap based grease Installed depth of bearing a 4 5 mm 0...

Page 198: ...ing arms NOTE When installing the connecting arms lift up the swingarm 6 Tighten Connecting arm nuts T R Spacer bolt 16 Nm 1 6 m kg 11 ft lb T R Rear shock absorber assembly lower nut 40 Nm 4 0 m kg 29 ft lb T R Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 32 ft lb T R Rear shock absorber assembly bracket nut 52 Nm 5 2 m kg 37 ft lb T R Connecting arm nuts 40 Nm 4 0 m kg 29 ft lb 1 ...

Page 199: ...ng locknut 2 2 Drive chain puller 2 3 Drive chain adjusting bolt 2 4 Rear fender 1 5 Drive chain guard 1 6 Drive chain guide swingarm side 1 7 Drive chain 1 8 Swingarm pivot shaft nut 1 9 Washer 1 10 Swingarm pivot shaft ring nut 1 11 Washer 1 12 Swingarm pivot shaft 1 4 16 9 14 14 20 13 15 19 17 6 5 3 10 12 8 3 2 18 11 1 1 2 LS LS 20 19 7 LS LS New New LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 N...

Page 200: ...lation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 4 16 9 14 14 20 13 15 19 17 6 5 3 10 12 8 3 2 18 11 1 1 2 LS LS 20 19 7 LS LS New New LS LS LS 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 70 Nm 7 0 m kg 50 ft lb T R 95 Nm 9 5 m kg 68 ft Ib ...

Page 201: ...t is not smooth or if there is binding check the spacers bear ings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 70 4 Remove Swingarm pivot shaft ring nut 1 NOTE Loosen the swingarm pivot shaft ring nut with the ring nut wrench 2 5 Remove Swingarm pivot shaft 1 NOTE Loosen the swingarm pivot shaft with the damp er rod holder 24 mm 2 EAS23360 CHECKING THE ...

Page 202: ...E Tighten the swingarm pivot shaft with the damp er rod holder 24 mm 2 4 Install Swingarm pivot shaft ring nut 1 Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease Installed depth of bearing a 0 1 0 mm 0 0 04 in Installed depth of bearing b 4 0 mm 0 16 in Installed depth of oil seal c 1 0 mm 0 04 in 5 Swingarm 6 Swingarm pivot shaft 7 Bolt A Left side B Right sid...

Page 203: ...ing nut wrench 2 5 Install Swingarm pivot shaft nut NOTE Lubricate the swingarm pivot shaft nut threads and mating surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 T R Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 68 ft lb Ring nut wrench 90890 01507 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 2 1 ...

Page 204: ...tom cowling Refer to GENERAL CHASSIS on page 4 1 Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Drive sprocket cover 1 2 Drive sprocket nut 1 3 Washer 1 4 Drive chain guide drive sprocket side 1 5 Drive sprocket 1 6 Drive chain 1 For installation reverse the removal proce dure New LT LT LT LT 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 85 Nm 8 5 m kg 61 ft Ib 1 5 4 3 2 6 ...

Page 205: ...es length b between pin outer sides 2 NOTE When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the...

Page 206: ... set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 14 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut St...

Page 207: ...CHAIN DRIVE 4 72 1 2 3 a a New ...

Page 208: ...CHAIN DRIVE 4 73 ...

Page 209: ...CYLINDER HEAD 5 16 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 CHECKING THE VALVE LIFTERS 5 23 INSTALLING THE VALVES 5 23 GENERATOR AND STARTER CLUTCH 5 26 REMOVING THE GENERATOR 5 28 CHECKING THE STARTER CLUTCH 5 28 INSTALLING THE STARTER CLUTCH 5 28 INSTALLING THE GENERATOR 5 29 PIC...

Page 210: ...E OIL PAN 5 53 CHECKING THE OIL PUMP 5 53 CHECKING THE RELIEF VALVE 5 53 CHECKING THE OIL PIPES 5 54 CHECKING THE OIL STRAINER 5 54 ASSEMBLING THE OIL PUMP 5 54 INSTALLING THE OIL PAN 5 54 CRANKCASE 5 55 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 CHECKING THE OIL PIPE 5 57 CHECKING THE TIMING CHAIN 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 59 REMOVING THE C...

Page 211: ... 5 71 REMOVING THE TRANSMISSION 5 76 CHECKING THE SHIFT FORKS 5 76 CHECKING THE SHIFT DRUM ASSEMBLY 5 76 CHECKING THE TRANSMISSION 5 77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 77 INSTALLING THE TRANSMISSION 5 78 ...

Page 212: ...r 1 6 Gasket 1 7 O2 sensor 1 8 Exhaust pipe assembly 1 9 Gasket 4 10 Exhaust pipe assembly bracket left lower side 1 11 Exhaust pipe assembly bracket left upper side 1 LS LT 12 10 1 2 3 5 4 6 8 8 7 9 New LT T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 45 Nm 4 5 m kg 32...

Page 213: ...pipe assembly Order Job Parts to remove Q ty Remarks LS LT 12 10 1 2 3 5 4 6 8 8 7 9 New LT T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 13 16 14 15 3 2 T ...

Page 214: ...THERMOSTAT on page 6 7 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 9 Drive sprocket Refer to CHAIN DRIVE on page 4 69 1 Shift rod 1 2 Shift arm 1 3 Oil filter cartridge 1 4 Oil filter cartridge bolt 1 5 Crankcase breather hose 1 6 Negative battery terminal 1 Disconnect 5 6 7 11 15 15 12 13 14 10 9 8 2 1 4 3 T R 10 Nm 1 ...

Page 215: ...h cable 1 Disconnect 14 Cylinder identification sensor coupler 1 Disconnect 15 Ignition coil coupler 4 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 5 6 7 11 15 15 12 13 14 10 9 8 2 1 4 3 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 10 Nm 1 0 m kg 7 2 ft Ib New New LS ...

Page 216: ...r side 1 6 Engine mounting collar outside 1 7 Engine mounting collar inside 1 8 Engine mounting bolt rear upper side 1 9 Engine mounting nut rear lower side 1 10 Engine mounting collar outside 1 11 Engine mounting collar inside 1 12 Engine mounting bolt rear lower side 1 13 Engine 1 For installation reverse the removal proce dure 1 2 3 9 1011 5 6 7 1 13 2 3 4 4 8 12 T R 45 Nm 4 5 m kg 32 ft Ib T R...

Page 217: ...ass the drive axle through the drive chain when installing the engine 1 Do not fully tighten the bolts and nuts 2 Tighten Engine mounting nut rear lower side 6 Engine mounting nut rear upper side 7 Engine mounting bolts front left side 8 Engine mounting bolts front right side 11 3 Install Shift arm 1 NOTE Install the shift arm 1 with its punch mark a aligned with the notch b in end of the shift sh...

Page 218: ...cut off valve Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 13 1 Ignition coil 4 2 Spark plug 4 3 Cylinder identification sensor 1 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide upper side 1 For installation reverse the removal proce dure 2 1 4 6 3 6 6 5 New New LT LT LS T R 8 Nm 0 8 m kg 5 8 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib...

Page 219: ... gasket 1 4 Intake camshaft cap 3 5 Exhaust camshaft cap 3 6 Camshaft sprocket 2 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Pin 2 10 Timing chain guide intake side 1 11 Timing chain guide exhaust side 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 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New 4 1 6 2 3 10 9 7 5 5 5 10 10 8...

Page 220: ...he camshaft lobes are turned away from each other 3 Remove Camshaft caps 1 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 4 Remove Intake camshaft Exhaust camshaft NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 1 EAS23850 CHECK...

Page 221: ...s out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Intake A 33 725 33 875 mm 1 3278 1 3337 in Limit 33 675 mm 1 3258 in Intake B 25 225 25 325 mm 0 9931 0 9970 in Limit 25 175 mm 0 9911 in Exhaust A 32 925 33 075 mm 1 2963 1 3022 in Lim...

Page 222: ...ear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Remove Timing chain tensioner rod 1 Timing chain tensioner spring seat 2 Timing chain tensioner inner spring 3 Timing chain tensioner outer spring 5 Timing chain tensioner housing 6 NOTE Squeeze the timing chain tensioner clip 4 and then remove the timing chain tensioner springs and timing chain tensioner rod 2 Check T...

Page 223: ...ip while pushing the rod into the housing other wise the rod may be ejected c Hook the clip 4 to the timing chain tensioner rod 3 NOTE Hook the timing chain tensioner rod pin 5 to the center of the clip 4 After the installation check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation EAS24010 INSTALLING THE CAMSHAFTS 1 Align T...

Page 224: ... cam shaft points towards the right side of the en gine 4 Install Camshaft cap bolts CAUTION ECA13730 The camshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshafts will result NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out 5 Install Timing chain tensioner gasket 1 Timing chain tensioner 2 NOTE ...

Page 225: ... on the pickup rotor is aligned with the crankcase mating surface b Camshaft sprocket match mark c Make sure the marks on the camshaft sprockets are aligned with the edge of the cyl inder head d Out of alignment Adjust Refer to the installation 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...

Page 226: ...TS on page 5 7 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure 1 2 3 4 T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 42 Nm 4 2 m kg 30 ft lb T R 1st 30 Nm 3 0 m kg 22 ft lb 2nd 60 Nm 6 0 m kg 43 ft lb T R 18 Nm 1 8 m kg 13 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New New 8 T R 20 Nm 2 0 m kg 14 ft Ib E E E ...

Page 227: ...eposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To...

Page 228: ...nuts cap nuts and bolts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head cap nut 1st 30 Nm 3 0 m kg 22 ft lb Cylinder head cap nut final 60 Nm 6 0 m kg 43 ft lb T R Cylinder head bolt 12 Nm 1 2 m kg 8 7 ft lb 8 6 2 4 10 9 3 1 5 7 12 11 ...

Page 229: ...n page 5 15 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 1 2 3 3 4 5 9 10 1 2 3 3 4 6 9 10 7 8 11 12 E New New M M E M M M M M ...

Page 230: ... 21 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 1 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 spri...

Page 231: ...nd valve guide remover 1 c After installing the valve guide bore the 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 ...

Page 232: ...minate 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 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 041...

Page 233: ...l the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean of...

Page 234: ...ollowing procedure applies to all of the 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 Free length intake 37 47 mm 1 48 in Limit 35 60 mm 1 40 in Free length exhaust 37 67 mm 1 48 in Limit 35 79 mm 1 42 in Installed compression spring force intake 166 00 190 00 N 37 32 42 71 lb 16 93 19 37 kgf Insta...

Page 235: ...lve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger b Smaller pitch Valve sp...

Page 236: ...VALVES AND VALVE SPRINGS 5 25 Each valve lifter and valve pad must be rein stalled in its original position ...

Page 237: ...E OIL on page 3 11 1 Stator coil assembly coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Stator coil assembly lead holder 1 6 Stator coil assembly 1 7 Starter clutch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor 1 10 Starter clutch 1 3 2 6 5 4 8 7 11 10 9 4 1 New New New LT LT E 9 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 ...

Page 238: ...reverse the removal proce dure Removing the generator and starter clutch Order Job Parts to remove Q ty Remarks 3 2 6 5 4 8 7 11 10 9 4 1 New New New LT LT E 9 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 12 Nm 1 2 m kg 8 7 ft Ib T R 70 Nm 7 0 m kg 50 ft lb E E ...

Page 239: ...tch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the gen erator rotor 2 and hold the generator rotor b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the...

Page 240: ...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 T R Generator rotor bolt 70 Nm 7 0 m kg 50 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A a 1 New 1 2 3 Yamaha bond No 1215 90890...

Page 241: ...R AND STARTER CLUTCH on page 5 26 1 Clutch cable 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Pickup rotor cover 1 4 Pickup rotor cover gasket 1 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT LT 1 3 3 5 4 2 6 LS New New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg...

Page 242: ...ickup rotor align the groove a in the crankshaft with the projection b on 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 coil rotor bolt 35 Nm 3 5 m kg 25 ft lb Sh...

Page 243: ...PICKUP ROTOR 5 32 ...

Page 244: ...er seat Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 4 Fuel tank Refer to FUEL TANK on page 7 1 Thermostat Refer to THERMOSTAT on page 6 7 1 Starter motor lead 1 2 Starter motor assembly 1 For installation reverse the removal proce dure 1 2 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 245: ...rks 1 O ring 1 2 Starter motor front cover 1 3 Lock washer 1 4 Oil seal 1 5 Bearing 1 6 Washer set 1 7 Starter motor yoke 1 8 Armature assembly 1 9 Gasket 2 10 Washer set 2 11 Brush holder along with the brushes 1 12 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 246: ... commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica u...

Page 247: ...SSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 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 front and starter motor rear covers ...

Page 248: ...on page 3 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Water pump breather hose 1 Disconnect 2 Clutch cable 1 Disconnect 3 Pull lever 1 4 Pull lever spring 1 5 Clutch cover 1 6 Clutch cover gasket 1 7 Dowel pin 2 For installation reverse the removal proce dure 5 2 6 7 1 3 4 7 LT New New LT New LS 7 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...

Page 249: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure LS New New E 5 4 3 2 LS 1 ...

Page 250: ...e 1 1 6 Friction plate 2 7 black painting 7 Clutch plate 2 1 8 Clutch plate 3 6 9 Friction plate 3 1 purple painting 10 Clutch boss nut 1 11 Spring 3 12 Clutch boss 1 13 Clutch boss plate 1 14 Washer 1 15 Thrust washer 1 1 16 Spacer 1 1 2 3 4 5 6 6 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E 6 E E T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 ...

Page 251: ...rive chain guide 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 6 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E 6 E E T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 115 Nm 11 5 m kg 85 ft lb ...

Page 252: ...TION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch pl...

Page 253: ...ing the clutch plate s be sure to replace the clutch plate 1 first After replacing the clutch plate 1 if specifications cannot be met replace the clutch plate 2 EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutc...

Page 254: ...URE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the cl...

Page 255: ...nstall the chain onto the oil pump driven sprocket while installing the clutch housing onto the main axle Make sure that the oil pump drive chain passes through the oil pump drive chain guide 2 Install Clutch boss plate 1 Clutch boss 2 NOTE Fit the projections a on the clutch boss into the grooves b in the clutch boss plate 3 Install Springs 1 NOTE Stack the springs on top of each other making sur...

Page 256: ...plate with one of the three punch marks b in the clutch boss 8 Install Seat plate Clutch springs Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Dowel pins Clutch cover gasket Clutch cover 1 NOTE Position the pull rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply locking agent LOCTITE to the thr...

Page 257: ...er is facing up When installing the pull lever push it and check that its punch mark b aligns with the mark c on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 1 a New c 1 2 b a ...

Page 258: ...E REMOVAL on page 5 1 Clutch housing Refer to CLUTCH on page 5 37 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Spacer 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 3 10 9 7 6 5 4 13 13 12 2 1 8 11 LS New New New LT E E T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 259: ...Bearing 2 For installation reverse the removal proce dure Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks 3 10 9 7 6 5 4 13 13 12 2 1 8 11 LS New New New LT E E T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 260: ...ar Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Shift shaft spring 2 NOTE Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring onto the shift shaft spring stopper Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift d...

Page 261: ...ER PUMP on page 6 9 Clutch housing Refer to CLUTCH on page 5 37 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Bottom cowling bracket 2 5 Oil pan 1 6 Oil pan gasket 1 7 Oil strainer 1 8 Oil strainer gasket 1 8 10 13 6 5 12 7 9 7 9 11 10 4 4 2 1 3 11 4 5 4 2 3 New New New New New New LS LS LS LS LT New New 10 E LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 ...

Page 262: ...verse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks 8 10 13 6 5 12 7 9 7 9 11 10 4 4 2 1 3 11 4 5 4 2 3 New New New New New New LS LS LS LS LT New New 10 E LT T R 10 Nm 1 0 m kg 7 2 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 12 Nm 1 2 m kg 8 7 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 263: ... 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 housing 1 8 Oil pump driven sprocket 1 For assembly reverse the disassembly pro cedure ...

Page 264: ... housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 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 1 Inner rotor 2 Outer rotor 3 Oil pump housin...

Page 265: ...haft with the recommended lubricant 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 53 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan ...

Page 266: ... pump drive chain guide Refer to CLUTCH on page 5 37 Oil pump assembly Refer to OIL PUMP on page 5 50 1 Timing chain 1 2 Dipstick 1 3 Neutral switch lead 1 4 Neutral switch 1 5 Ventilation chamber cover 1 6 Ventilation chamber cover gasket 1 7 Oil pipe 1 8 Oil baffle plate 1 1 11 4 3 2 11 6 10 1 8 9 7 5 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm ...

Page 267: ...g the crankcase Order Job Parts to remove Q ty Remarks 11 4 3 2 11 6 10 1 8 9 7 5 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 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 T R 20 Nm 2 0 m kg 14 ft Ib LS New New New New New LS LS LS LT LT LT LT 3 LT T R 12 Nm 1 2 m kg 8 7 ft Ib 4 ...

Page 268: ... halves in a mild solvent 2 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 PIPE 1 Check Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS25620 CHECKING THE TIMING CHAIN Refer to CAMSHAFTS on page 5 7 EAS25640 ASSEMBLIN...

Page 269: ...55 mm bolts 15 22 27 M6 45 mm bolts 17 19 7 Tighten Crankcase bolts 1 10 Loosen all bolts following the tightening or der and then tighten to specification torque NOTE Tighten the bolts in the tightening sequence cast on the crankcase 8 Tighten Crankcase bolts 11 28 NOTE Tighten the bolts in the tightening sequence cast on the crankcase T R Crankcase bolt M8 115 mm M8 85 mm 1st 20 Nm 2 0 m kg 14 f...

Page 270: ...to CRANKCASE on page 5 55 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 New E New E New New New E M M T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd Specified angle 175 185 E 7 6 5 4 9 8 10 3 3 1 2 M M New ...

Page 271: ... 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 th...

Page 272: ...earance 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 2 Install Piston ring into the cylinder Bore 67 000 67 010 mm 2 6378 2 6382 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 ...

Page 273: ...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 25 0 35 mm 0 0098 0 0138 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 70 0 80 mm 0 0276 0 0315 in Limit 1 00 mm 0 0394 in Oil ring End g...

Page 274: ... b 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 ...

Page 275: ...pper 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 or numbers a 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 left when the punch mark b on the pis ton is pointing up Refe...

Page 276: ...nd connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings one hand install the connecting rod assembly into the cyl inder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure the characters b on both the con necting rod and connecting rod cap are aligned 8 Tighten C...

Page 277: ...rther to reach the specified angle 175 185 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 nut note th...

Page 278: ...ks Crankcase Separate Refer to CRANKCASE on page 5 55 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 59 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 1 2 3 E E E 4 New LS ...

Page 279: ...asure Crankshaft journal to crankshaft 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 cranks...

Page 280: ...f the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the cran...

Page 281: ...al upper bearings into the upper crankcase Crankshaft journal lower bearings into the lower crankcase 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 282: ... assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 2 6 Spring 2 7 Shift fork guide bar 2 8 Shift fork L 1 9 Shift fork R 1 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 13 Oil pipe 1 14 Bearing 1 E E E E 12 11 7 13 5 6 7 6 10 5 4 9 8 1 2 3 15 14 LT LT E E LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E New T R 10 Nm 1 0 m kg 7 2 ft Ib 3 New...

Page 283: ...dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks E E E E 12 11 7 13 5 6 7 6 10 5 4 9 8 1 2 3 15 14 LT LT E E LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E New T R 10 Nm 1 0 m kg 7 2 ft Ib 3 New LS LS ...

Page 284: ... 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd 4th pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure M M M M E 1 2 3 4 5 8 9 6 7 10 13 14 15 12 11 New New ...

Page 285: ...1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 E M 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 20 M M M 7 New New New M M ...

Page 286: ...Collar 1 20 Bearing 1 21 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks E M 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 20 M M M 7 New New New M M ...

Page 287: ...ng procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the s...

Page 288: ...ded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace ET2C01015 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be su...

Page 289: ...side and install it close to the right side end of the crankcase 2 Install Main axle assembly 1 NOTE Stake the main axle assembly bearing housing bolts 2 at a cutout a in the main axle assem bly bearing housing 3 3 Install Shift fork C 1 Shift drum assembly 2 Shift fork guide bar 3 NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following s...

Page 290: ...roove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the drive axle bearing circlip 4 is inserted into the grooves d in the upper crankcase T R Shift drum retainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 1 2 d 4 5 b a 3 3 c c ...

Page 291: ... 6 3 INSTALLING THE RADIATOR 6 3 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 6 8 WATER PUMP 6 9 CHECKING THE WATER PUMP 6 10 INSTALLING THE WATER PUMP 6 10 ...

Page 292: ...reservoir hose 1 3 Coolant reservoir 1 4 Radiator fan motor coupler 2 Disconnect 5 Radiator cap 1 6 Radiator 1 7 Radiator fan 2 8 Radiator inlet hose 1 9 Radiator inlet pipe 1 10 Radiator outlet hose holder 1 11 Radiator outlet hose 1 12 Radiator outlet pipe 1 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 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...

Page 293: ...e dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 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 13 Nm 1 3 m kg 9 4 ft Ib 4 7 7 4 9 12 10 11 6 8 1 3 2 5 13 3 3 ...

Page 294: ...nd 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 29 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 B...

Page 295: ...NGING THE COOLANT on page 3 19 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Oil cooler outlet hose 1 2 Oil cooler inlet hose 1 3 Water jacket joint 1 4 O ring 1 5 Water jacket joint inlet hose 1 6 Water pump outlet pipe 1 7 Oil cooler union bolt 1 8 Gasket 1 9 Oil cooler 1 T R 63 Nm 6 3 m kg 45 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New New LS LS 4 3 5 6 2 7 9 10 8 1 E New ...

Page 296: ...O ring 1 For installation reverse the removal proce dure Removing the oil cooler Order Job Parts to remove Q ty Remarks T R 63 Nm 6 3 m kg 45 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New New LS LS 4 3 5 6 2 7 9 10 8 1 E New ...

Page 297: ...lling the oil cooler lubricate the its union bolt with a thin coat of engine oil Make sure the O ring is positioned properly Make sure the projection a on the oil cooler touches the projection b on the crankcase 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 Re...

Page 298: ...filter case Refer to AIR FILTER CASE on page 7 4 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Coolant temperature sensor coupler 1 Disconnect 2 Thermostat outlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib 3 4 2 1 ...

Page 299: ...lace it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or r...

Page 300: ... Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 4 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Clutch cable 1 Disconnect 2 Water pump inlet hose 1 3 Water pump outlet hose 1 4 Water pump breather hose 1 5 Water pump assembly 1 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib New LS LT LT LT T R 12 Nm 1 2 m kg 8 7 ft...

Page 301: ...2 NOTE Align the slit a on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified p...

Page 302: ...WATER PUMP 6 11 ...

Page 303: ... FUEL RAIL 7 6 CHECKING THE SECONDARY INJECTORS 7 6 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 7 6 THROTTLE BODIES 7 7 CHECKING THE PRIMARY INJECTORS 7 10 CHECKING THE THROTTLE BODIES 7 10 CHECKING THE FUEL PRESSURE 7 10 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 7 10 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 7 11 INST...

Page 304: ...sconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel tank overflow hose 1 Disconnect 6 Fuel tank breather hose 1 Disconnect 7 Fuel tank 1 8 Fuel tank upper cover 1 9 Fuel tank overflow hose fuel tank to hose joint 1 10 Fuel tank breather hose fuel tank to hose joint 1 11 Fuel pump 1 12 Battery cover 1 For installation reverse the removal proce dure 4 6 11 6 3 5 2 9 1 8 10 7 12 1 New T R 4 Nm 0 4 m kg ...

Page 305: ...illus tration Make sure that the fuel pipe does not contact the ground otherwise the fuel pump could be damaged EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly...

Page 306: ...C2C01017 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of ...

Page 307: ...el rail 1 Disconnect 6 Upper air filter case 1 7 Secondary injector holder 1 8 Cylinder 1 secondary injector coupler 1 Disconnect 9 Cylinder 2 secondary injector coupler 1 Disconnect 10 Cylinder 3 secondary injector coupler 1 Disconnect 11 Cylinder 4 secondary injector coupler 1 Disconnect 12 Sub wire harness 3 1 13 Secondary injector fuel rail 1 14 Secondary injector 4 6 16 19 19 17 5 4 18 3 1 15...

Page 308: ...r case joint lower 2 For installation reverse the removal proce dure Removing the air filter case and secondary injectors Order Job Parts to remove Q ty Remarks 6 16 19 19 17 5 4 18 3 1 15 5 3 3 9 4 7 9 8 12 10 11 13 14 14 14 14 2 New New New New New T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LT T R 2 Nm 0 2 m kg 1 4 ft Ib T R 1 5 Nm 0 15 m kg 1 08 ft lb ...

Page 309: ...sing any tools Before removing the hose place a few rags in the area under where it will be removed ET2C01017 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Damage Replace ET2C01006 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 1 Connect Fuel hose primary injector fuel rail to second ary injector fuel rail CAUTION EC2C01017 When installing the fuel hose ma...

Page 310: ...t 2 Throttle position sensor for throttle cable pulley coupler 1 Disconnect 3 Throttle position sensor for throttle valves cou pler 1 Disconnect 4 Sub wire harness 2 coupler 1 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Fuel hose primary injector fuel rail to second ary injector fuel rail 1 7 Fuel hose fuel tank to primary injector fuel rail 1 8 Throttle cable decelerator cable ...

Page 311: ...int clamp 4 12 Heat protector 1 13 Throttle body joint 4 For installation reverse the removal proce dure Removing the throttle body assembly Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib 7 10 3 2 1 5 8 8 11 4 12 6 9 13 ...

Page 312: ...arness 2 1 7 Intake air pressure sensor hose 7 8 Intake air pressure sensor 1 9 Primary injector fuel rail 1 10 Primary injector 4 11 Throttle position sensor for throttle valves 1 12 Throttle position sensor for throttle cable pulley 1 13 Throttle bodies 1 CAUTION ECA14600 The throttle bodies should not be disas sembled For installation reverse the removal proce dure New New New 5 10 8 7 7 7 6 12...

Page 313: ...hem Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses c Connect the pressure gauge 2 and adapter 3 to the fuel hose fuel tank to primary injec tor fuel rail d Start the engine e Measure the fuel pressure Faulty Replace the fuel pump ET2C01007 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Check Throttle position sensor for throttle valves Refe...

Page 314: ...position sensor angle a Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circuit tester to the throttle position sensor c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position senso...

Page 315: ...o install the throttle body joints with the L mark onto the throttle body openings for cyl inders 1 and 2 and the joints with the R mark onto the openings for cylinders 3 and 4 T R Throttle body joint bolt 10 Nm 1 0 m kg 7 2 ft lb L R 1 ...

Page 316: ...AIR INDUCTION SYSTEM 7 13 EAS27040 AIR INDUCTION SYSTEM 2 1 2 4 3 4 3 6 4 5 A A ...

Page 317: ...M 7 14 1 Lower air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to cylinder head cover 5 Reed valve assembly 6 Exhaust port ...

Page 318: ... FILTER CASE on page 7 4 1 Air induction system cover 1 2 Immobilizer unit coupler holder 1 3 Air induction system solenoid coupler 1 Disconnect 4 Air induction system hose air filter case to air cut off valve 1 5 Air induction system hose air cut off valve to cylinder head cover 2 6 Air cut off valve 1 For installation reverse the removal proce dure 1 5 5 6 4 3 2 ...

Page 319: ...alves Order Job Parts to remove Q ty Remarks 1 Reed valve cover 2 2 Reed valve assembly 2 3 Reed valve plate 4 For installation reverse the removal proce dure 1 3 LT LT LT LT 1 2 2 3 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 320: ...s 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 assembly until the temperature be comes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Che...

Page 321: ...ALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 SELF DIAGNOSTIC FUNCTION TABLE 8 36 TROUBLESHOOTING METHOD 8 39 DIAGNOSTIC MODE 8 40 TROUBLESHOOTING DETAILS 8 48 FUEL PUMP SYSTEM 8 73 CIRCUIT DIAGRAM 8 73 TROUBLESHOOTING 8 75 IMMOBILIZER SYSTEM...

Page 322: ...CTIFIER REGULATOR 8 104 CHECKING THE HORN 8 104 CHECKING THE OIL LEVEL SWITCH 8 105 CHECKING THE FUEL SENDER 8 105 CHECKING THE SPEED SENSOR 8 106 CHECKING THE RADIATOR FAN MOTORS 8 106 CHECKING THE COOLANT TEMPERATURE SENSOR 8 106 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 8 107 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 8 107 CHECKING THE FUEL PUMP 8 108 CHECK...

Page 323: ......

Page 324: ... W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE B...

Page 325: ...ground 14 Relay unit 17 Neutral switch 18 Sidestand switch 23 ECU engine control unit 24 Spark plug 25 Cylinder 1 ignition coil 26 Cylinder 2 ignition coil 27 Cylinder 3 ignition coil 28 Cylinder 4 ignition coil 41 Crankshaft position sensor 48 Lean angle sensor 66 Engine stop switch ...

Page 326: ...om producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open 1 4 5 10 12 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Mai...

Page 327: ...ERY on page 8 96 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 102 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 102 Replace the ignition coil s 6 Chec...

Page 328: ...ck the sidestand switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 101 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 103 Replace the lean angle sensor 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 ...

Page 329: ...IGNITION SYSTEM 8 6 ...

Page 330: ...G Y B Y B Y R Y B Y B G L R L R L R L R L R L Y2 L W Br W Br W G W R G B R R L BLACK BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK Dg Y W YBr WR Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLACK BROWN R W R G B2 B1 BB3 BB2 BB1 BB4 Br L Br L Br R R W B Br W W W Br R Br L Br L Br R Y R Y R Y R W B G B G ...

Page 331: ... switch 4 Ignition fuse 6 Main fuse 7 Battery 8 Starter relay 10 Starter motor 11 Engine ground 14 Relay unit 15 Starting circuit cut off relay 17 Neutral switch 18 Sidestand switch 66 Engine stop switch 67 Start switch 74 Clutch switch ...

Page 332: ...osed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions ...

Page 333: ... THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 Engine ground ...

Page 334: ...ERY on page 8 96 Clean the battery terminals Recharge or replace the battery 3 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 99 Replace the relay unit 4 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 101 Replace the relay unit 5 Check the starter relay Refer to CHECKING THE RE LAYS on page 8 99 Replace the starter relay 6 C...

Page 335: ...he clutch switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the clutch switch 11 Check the start switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the right handlebar switch 12 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 35 Repair or replace the starter motor 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 Properly conn...

Page 336: ...R W R B B Br 187 187 R R R R R W L W B B2 R G Y L Lg R W B B2 R G Y L Lg R W B B2 Lg Y L R W R G B Br Br R R R R R B W W W W W W R R R R R B B B B A R W L W2 R B G Y L W BLACK R W L W3 R W BLUE BLUE R W R G B2 B1 BB3 BB2 BB1 BB4 Br L Br L Br R R W B Br W W W Br R Br L Br L Br R Y R Y R Y L R W W W B R W W W 65 64 66 67 14 13 6 2 5 4 3 1 8 9 7 10 12 11 89 90 91 92 ...

Page 337: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 6 Main fuse 7 Battery 11 Engine ground ...

Page 338: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 96 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 103 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 104 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUI...

Page 339: ...CHARGING SYSTEM 8 16 ...

Page 340: ...R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK B...

Page 341: ...ne control unit 59 High beam indicator light 62 Meter light 71 Pass switch 72 Dimmer switch 81 Headlight low beam 82 Headlight high beam 83 Auxiliary light 84 License plate light 86 Tail brake light 87 Headlight relay on off 88 Headlight relay dimmer 90 Taillight fuse 92 Headlight fuse ...

Page 342: ...e bulb s and bulb socket s 2 Check the fuses Main headlight and taillight Refer to CHECKING THE FUS ES on page 8 95 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 96 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the main switch immobilizer unit 5 Check the dimmer s...

Page 343: ...ght relay dimmer Refer to CHECKING THE RE LAYS on page 8 99 Replace the headlight relay dimmer 9 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting sys tem s wiring This circuit is OK ...

Page 344: ...B R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BL...

Page 345: ...cator light 54 Tachometer 55 Shift timing indicator light 56 Multi function meter 58 Coolant temperature warning light 60 Left turn signal indicator light 61 Right turn signal indicator light 63 Oil level switch 65 Front brake light switch 68 Turn signal hazard relay 70 Hazard switch 73 Horn switch 75 Turn signal switch 76 Horn 77 Rear right turn signal light 78 Rear left turn signal light 79 Fron...

Page 346: ...eplace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 96 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the main switch immobilizer unit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiri...

Page 347: ...S on page 8 91 Replace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 94 Replace the turn signal light bulb s sock et s or both 2 Check the turn signal switc...

Page 348: ...switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 101 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 105 Replace the oil level switch 2 Check the entire...

Page 349: ...06 Replace the coolant temperature sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 106 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect ...

Page 350: ...SIGNALING SYSTEM 8 27 NG OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK ...

Page 351: ...SIGNALING SYSTEM 8 28 ...

Page 352: ...G W R G B R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE B...

Page 353: ...use 6 Main fuse 7 Battery 11 Engine ground 23 ECU engine control unit 43 Coolant temperature sensor 93 Radiator fan motor relay 94 Right radiator fan motor fuse 95 Left radiator fan motor fuse 96 Right radiator fan motor 97 Left radiator fan motor ...

Page 354: ...3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 106 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 99 Replace the radiator fan motor relay 6 Check the coolant temperature Refer to CHECKING TH...

Page 355: ...COOLING SYSTEM 8 32 ...

Page 356: ...2 L W Br W Br W G W R G B R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 Lg Lg B Lg Lg R L L L G Lg R W W W W R W R B L B L R L B L B L G L L BLACK BLACK BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BL...

Page 357: ...ylinder 2 ignition coil 27 Cylinder 3 ignition coil 28 Cylinder 4 ignition coil 29 Primary injector 1 30 Primary injector 2 31 Primary injector 3 32 Primary injector 4 33 Secondary injector 1 34 Secondary injector 2 35 Secondary injector 3 36 Secondary injector 4 37 Throttle servo motor 38 Air induction system solenoid 39 EXUP servo motor 40 O2 sensor 41 Crankshaft position sensor 42 Air temperatu...

Page 358: ...fuel reserve tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on f...

Page 359: ...ymptom Able un able to start Able un able to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driv en Unable Able 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 Int...

Page 360: ...from the O2 sensor Able Able 30 Lean angle sensor Latch up detected No normal signal is received from the lean angle sensor Unable Unable 33 Cylinder 1 ignition coil open circuit Primary lead of the cylinder 1 ig nition coil open circuit detected Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 34 Cylinder 2 ignition coil open circuit Primary lead...

Page 361: ...OM An error is detected while reading or writing on EEPROM CO ad justment value Able Able 46 Vehicle system power supply monitoring voltage Power supply is not normal Able Able 50 ECU internal malfunc tion ECU memory is faulty When this malfunction is detected in the ECU the fault code number might not appear on the meter Able Un able Able Un able 59 Throttle position sen sor for throttle cable pu...

Page 362: ...agnostic mode Refer to Sensor operation table and Actuator oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unable Unabl...

Page 363: ... the clock LCD 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET buttons NOTE To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT but...

Page 364: ...ction is loose Open or short circuit in wire harness Defective throttle position sensor for throt tle valves Malfunction in ECU Improperly installed throttle position sensor for throttle valves 01 13 17 EXUP servo motor circuit open or short circuit detect ed or loose connection Open or short circuit in wire harness Defective EXUP servo motor potentiome ter circuit 53 18 EXUP servo motor is stuck ...

Page 365: ...cuit in wire harness Malfunction in ignition coil Malfunction in ECU 31 35 Open circuit detected in the primary lead of the cylin der 3 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 32 36 Open circuit detected in the primary lead of the cylin der 4 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 33 39 Open circ...

Page 366: ...Defective throttle position sensor Improperly installed throttle position sensor Malfunction in ECU 14 15 60 Throttle servo motor open or short circuit detect ed Defective throttle servo mo tor Malfunction in ECU servo motor driving system Open or short circuit in wire harness Defective throttle servo motor potentiome ter circuit Stuck throttle servo motor mechanism Stuck throttle servo motor moto...

Page 367: ...ally mea sured air temperature with the meter display value 06 Coolant temperature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the meter display val ue 07 Vehicle speed pulse 0 999 Check that the number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Remove the l...

Page 368: ...ransmis sion in gear Stand retracted ON Stand extended OFF 21 Neutral switch Shift the transmission Neutral ON In gear OFF 60 EEPROM fault cylinder No No history 00 History exists 01 04 fault cylinder No If more than one cylinder is defective the display changes every two seconds to show all the detected cyl inder numbers When all cylinder numbers are shown the display re peats 61 Malfunction hist...

Page 369: ...ode numbers are shown the display re peats To reinstate set the engine stop switch from to 70 Control number 00 Diag nostic code No Item Meter display Checking method Diag nostic code No Item Actuation Checking method 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect...

Page 370: ... Actuates the primary injector 4 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 4 five times 40 Secondary injector 1 Actuates the secondary in jector 1 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the secondary injector 1 five times 41 Secondary injec...

Page 371: ...tion system solenoid five times 50 Fuel injection system relay Actuates the fuel injection system relay five times at one second intervals Illuminates 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 injection system relay five times 51 Radiator fan m...

Page 372: ... 2 Connections Cylinder identification sensor cou pler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers 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 cylinder identifica tion sensor coupler...

Page 373: ...Crankshaft position sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers 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 gr...

Page 374: ...is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler black blue black blue pink white pink white blue blue 3 Defective 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 8 110 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detache...

Page 375: ...ng the main switch to ON 2 Connections Throttle position sensor for throttle valves coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers 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 thrott...

Page 376: ...vo motor potenti ometer circuit Execute the diagnostic mode Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check t...

Page 377: ...uit Between ECU coupler and relay unit coupler blue yellow blue yellow Between relay unit coupler and sidestand switch coupler blue black blue black Between sidestand switch cou pler and engine ground black black 3 Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 8 91 Fault code No 20 Symptom When the main switch is turned to ON the atmospheric pressure sensor...

Page 378: ...sor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 106 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Air temperature sensor coupler Main wire harness...

Page 379: ...e pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Reinstated au tomatically if a normal signal is received 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between atmospheric pressure sensor coupler and ECU cou pler black blue black blue pink pink bl...

Page 380: ...tween O2 sensor coupler and ECU coupler gray green gray green black blue black blue pink black pink black red blue red blue 4 Check fuel pressure Refer to THROTTLE BODIES on page 7 7 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom Latch up detected No normal signal is received from the lean angle sensor Diagnostic code No 08 Lean angle sensor Order Item components and probable ...

Page 381: ...mary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 102 Fault code No 34 Symptom Open circuit detected in the primary lead of the cylinder 2 ignition coil Diagnostic code No 31 Cylinder 2 ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 2 ignition coil coupler Main wi...

Page 382: ...led out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the cylinder 3 ig nition coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler red black red blue orange green o...

Page 383: ... Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the cylinder 4 ig nition coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU cou pler main wire harness red black red blue gr...

Page 384: ...y be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the fuel injector couplers 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between primary injector cou pler and ECU coupler red blue red blue 1 red black red black 2 gr...

Page 385: ...led out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Execute the di agnostic mode Code No 63 Set the engine stop switch to 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between secondary injector coupler and ECU coupler red blue red blue 1 white blue white...

Page 386: ...that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Reinstated au tomatically if a normal signal is received 2 Open or short circuit in lead Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective...

Page 387: ... the speed sensor by operating the vehicle A 2 Connections Speed sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely A 3 Open or short circuit in lead Repair or replace if there is an open or short circuit Between speed sensor coupler and...

Page 388: ... switch coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely B 3 Open circuit in neutral switch lead Repair or replace if there is an open circuit Between neutral switch coupler and relay unit coupler sky blue sky blue Between relay unit coupler ...

Page 389: ...f there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON when the engine stop switch is set to 2 Open or short circuit in 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 starter relay coupler red red Between relay unit cou...

Page 390: ...urning the main switch to ON Readjust the exhaust gas volume after it is reinstated Fault code No 46 Symptom Power supply is not normal Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 13 Starting the en gine and oper ating it at idle 2 Open or shor...

Page 391: ... in the specified position Turning the main switch to ON 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers 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 a...

Page 392: ...t in wire harness Repair or replace if there is an open or short circuit Between throttle servo motor coupler and ECU coupler yellow red yellow red light green red light green red 4 Defective throttle servo motor Execute the diagnostic mode Code Nos 01 13 Replace the throttle body as sembly if defective 5 Malfunction in ECU Replace the ECU Fault code No Er 1 Symptom No signals are received from th...

Page 393: ...pler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the ...

Page 394: ...r assembly coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers 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 Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue 3 Malfunction i...

Page 395: ...FUEL INJECTION SYSTEM 8 72 ...

Page 396: ... R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK ...

Page 397: ...UMP SYSTEM 8 74 3 Main switch 4 Ignition fuse 6 Main fuse 7 Battery 9 Fuel injection system fuse 11 Engine ground 14 Relay unit 16 Fuel pump relay 19 Fuel pump 23 ECU engine control unit 66 Engine stop switch ...

Page 398: ...he battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 99 Replace the relay unit 6 Check the fuel pump ...

Page 399: ...FUEL PUMP SYSTEM 8 76 ...

Page 400: ...W R G B R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L B L B L G L L BLACK BLACK BLUE BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK Dg Y W Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLU...

Page 401: ...Main switch 4 Ignition fuse 5 Backup fuse odometer clock and immobilizer system 6 Main fuse 7 Battery 11 Engine ground 12 Immobilizer unit 23 ECU engine control unit 50 Immobilizer system indicator light 56 Multi function meter ...

Page 402: ...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 pla...

Page 403: ...n below 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 ke...

Page 404: ...h 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 th...

Page 405: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 406: ...Check the main switch Refer to CHECKING THE SWITCHES on page 8 91 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 77 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 83 Fault code Part Symptom Cause Ac...

Page 407: ...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 408: ...IMMOBILIZER SYSTEM 8 85 a Light on b Light off ...

Page 409: ...IMMOBILIZER SYSTEM 8 86 ...

Page 410: ...ELECTRICAL COMPONENTS 8 87 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ...

Page 411: ...7 Main fuse 8 Fuel injection system fuse 9 Starter relay 10 Neutral switch 11 EXUP servo motor 12 Rear brake light switch 13 O2 sensor 14 Sidestand switch 15 Speed sensor 16 Oil level switch 17 Ignition coil 18 Radiator fan motor 19 Rectifier regulator 20 Horn 21 Fuse box radiator fan motor signaling system ignition taillight headlight ...

Page 412: ...ELECTRICAL COMPONENTS 8 89 1 5 4 3 2 6 7 8 9 10 12 13 11 14 15 16 17 ...

Page 413: ...an angle sensor 7 Relay unit 8 Turn signal hazard relay 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 13 Throttle position sensor for throttle valves 14 Cylinder identification sensor 15 Radiator fan motor relay 16 Headlight relay dimmer 17 Headlight relay on off ...

Page 414: ... CHECKING THE SWITCHES Br R R Br L Dg Y W Y Br W R Y Ch L Y B B Y Br B B BLUE G Y L W R W R B B Br BLUE B B BROWN Br G Y 9 10 11 12 13 2 3 4 5 6 1 7 8 Sb R Y R B L W B ON OFF R Br L Br R Ch Br W Dg R Y W Y Y R Y Br B L Y2 B Y Ch Dg Br W ...

Page 415: ...tch switch 2 Main switch 3 Hazard switch 4 Pass switch 5 Dimmer switch 6 Horn switch 7 Turn signal switch 8 Sidestand switch 9 Front brake light switch 10 Engine stop switch 11 Start switch 12 Neutral switch 13 Rear brake light switch ...

Page 416: ...range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch positi...

Page 417: ...e condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW2C01001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC2C01002 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touc...

Page 418: ...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 Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electr...

Page 419: ... the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged accord ing to the instructions for the charging method If the battery is overcharged the electrolyte level will drop considerab...

Page 420: ...harger 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 time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it...

Page 421: ...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 chargi...

Page 422: ...circuit cut off relay Relay unit fuel pump relay Headlight relay on off 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 R R R W R 2 1 4 3 W L 1 Positive battery terminal 2 Negative battery terminal 3 Positive...

Page 423: ...lay output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery...

Page 424: ...probe ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 C...

Page 425: ...coil as shown b Measure the secondary coil resistance 3 Check Ignition spark gap Out of specification Replace a Connect the ignition checker 1 as shown b Turn the main switch to ON and engine stop switch to c Measure the ignition spark gap a Primary coil resistance 1 19 1 61 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red black 1 Negative tester probe orange o...

Page 426: ...Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown c Turn the main switch to ON d Turn the lean angle sensor to 65 e Measure the lean angle sensor output volt age EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator c...

Page 427: ...t the horn leads from the horn ter minals b Connect the pocket tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe white 2 Negative tester probe white 3 Charging voltage 14 V at 5000 r min Pocket t...

Page 428: ...m the wire harness 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance a Connect the pocket tester Ω 1 to the fuel sender terminal as shown b Measure the fuel sender resistance Oil level switch resistance Maximum level position 484 536 Ω Minimum level position 114 126 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive t...

Page 429: ...c Measure the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 7 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Ou...

Page 430: ...inal as shown b Measure the throttle position sensor for throttle valves maximum resistance 3 Install Throttle position sensor for throttle valves NOTE When installing the throttle position sensor for throttle valves adjust its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES on page 7 10 ET2C01001 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 1 ...

Page 431: ...s If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank 3 Check Fuel pump operation Faulty rough movement Replace a Fill the fuel tank b Put the end of the fuel hose 1 into an open container c Connect the batter...

Page 432: ...ylinder identification sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the cylinder identification sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown red 1 Negative tester probe red white 2 Atmospheric pressure sensor output voltage 3 15 4 15 V Pocket tester 90890 03112 Analog poc...

Page 433: ... subject the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check Air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the air temperature sensor terminal as shown b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do not ge...

Page 434: ...ELECTRICAL COMPONENTS 8 111 ...

Page 435: ...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 2 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 436: ...el pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition co...

Page 437: ...ve 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 Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Cl...

Page 438: ...ake 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 oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly Cra...

Page 439: ...t come on Wrong tail brake light LED Too many electrical accessories Incorrect connection Burnt out tail brake light LED Tail brake light bulb burnt out Wrong tail brake light LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect co...

Page 440: ...n signal indicator light 61 Right turn signal indicator light 62 Meter light 63 Oil level switch 64 Right handlebar switch 65 Front brake light switch 66 Engine stop switch 67 Start switch 68 Turn signal hazard relay 69 Left handlebar switch 70 Hazard switch 71 Pass switch 72 Dimmer switch 73 Horn switch 74 Clutch switch 75 Turn signal switch 76 Horn 77 Rear right turn signal light 78 Rear left tu...

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Page 442: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 443: ...R L R L R L Y2 L W Br W Br W G W R G B R W B W Y W B P W G W G W P B L L B L L P W R L R B R B L Y Y B Y L B Y L Y2 P B Lg Lg B Lg Lg P B R L L L G Lg R W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y W YBr WR Y Ch L Y2 B B Y Br BROWN BLA...

Page 444: ...OWN B BLACK BLUE BLUE BLACK BLUE BLUE BLACK GRAY GRAY BLACK BLACK GRAY GRAY BLACK BLACK DARK BLUE BLACK BLACK BLACK DARK GREEN BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLACK ON OFF C C C C B B A B D D D C D A A B E B C C F F F F D D D D C C F C GRAY GRAY GRAY GRAY GRAY GRAY GRAY GRAY D B A A A A A A A A A B B B 25 26 27 28 24 23 24 24 24 37 38 39 36 35 3...

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