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Yamaha 2008 YZF-R6X, Service Manual

The Yamaha 2008 YZF-R6X Service Manual is a comprehensive manual designed to provide users with detailed instructions for maintaining and repairing their motorcycle. This essential manual is available for free download at manualshive.com, ensuring easy access to reliable information on optimizing the performance of the YZF-R6X.

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FUEL TANK

7-1

EAS26620

FUEL TANK

Removing the fuel tank and fuel pump

Order

Job/Parts to remove

Q’ty

Remarks

Rider seat/Fuel tank bracket

Refer to “GENERAL CHASSIS” on page 4-1.

1

Fuel tank side cover

2

2

Fuel tank breather hose

1

Except for california 
Disconnect.

3

Fuel tank overflow hose

1

Disconnect.

4

Fuel pump coupler

1

Disconnect.

5

Fuel sender coupler

1

Disconnect.

6

Fuel hose connector cover

1

7

Fuel hose (fuel tank side)

1

Disconnect.

8

Fuel  tank

1

9

Fuel tank upper cover

1

10

Fuel tank overflow hose (fuel tank to hose joint)

1

11

Fuel tank breather hose (fuel tank to hose joint)

1

Except for california

12

Fuel tank breather hose (fuel tank to rollover 
valve

1

For california only

13

Fuel pump

1

For installation, reverse the removal proce-
dure.

Summary of Contents for 2008 YZF-R6X

Page 1: ...SERVICE MANUAL YZFR6X C 13S 28197 10 LIT 11616 21 61 2008 ...

Page 2: ... Yamaha Motor Corporation U S A First edition October 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 21 61 ...

Page 3: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable N...

Page 4: ...e v o c h c t u l C 5 1 t e k s a g r e v o c h c t u l C 6 2 n i p l e w o D 7 For installation reverse the removal proce dure 5 2 6 7 1 3 4 7 LT New New LT New LS T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib CLUTCH 5 40 EAS25070 REMOVING THE CLUTCH 1 Remove Oil strainer Refer to OIL PUMP on page 5 48 Water pump Refer to WATER PUMP on page 6 8 Friction pl...

Page 5: ...d 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 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease G M LS M E 9 10 11 16 17 18 B 13 12 14 15 LT New T R 1 2 3 4 5 6 7 8 BF 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part ...

Page 6: ......

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

Page 8: ......

Page 9: ...maha Chip Controlled Throttle YCC I Yamaha Chip Controlled Intake 1 4 INSTRUMENT FUNCTIONS 1 8 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: ...el ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions d...

Page 12: ...olant 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 deter mined through the signals from the crankshaft position sensor As a result the volume of fuel that is required by ...

Page 13: ...r easy to use torque even in a high revving engine The YCC I system calculates the value from the engine revolution number and throttle opening rate activates the intake air funnel with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds Aims and advantages of using YCC T system Increase...

Page 14: ...actical use range Intake pipe length switching control using the motor The intake pipe length switching operation in a minute time is now available by means of the motor drive using the electronic control The smooth power characteristic is provided which does not let an operator feel the switching action by the optimization of its switching revolution number and the most suitable application of en...

Page 15: ... CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sens ing 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 Atmospheric pressure sensor 19 Intake funnel servo mot...

Page 16: ...ral switch 7 Atmospheric pressure sensor 8 Accelerator position two signals 9 Throttle position 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 throttle valve opening angle 20 Base map 21 Air funnel position Calculation value 22 Inta...

Page 17: ...g indicator light control mode To switch the speedometer and odometer tripmeter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zer...

Page 18: ...ELECT 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 Push the SELECT button to stop the stop watch 3 Push the SELECT button again to reset the stopwatch Split time measurement 1 Push the RESET button to start the stop wa...

Page 19: ...should be checked as soon as pos sible in order to avoid engine damage Display brightness and shift timing indica tor light control mode This mode cycles through five control func tions allowing you to make the following set tings in the order listed below Display brightness This function allows you to adjust the bright ness of the displays and tachometer to suit the outside lighting conditions Sh...

Page 20: ...min and 18000 r min From 10000 r min to 13000 r min the indicator light can be set in increments of 500 r min From 13000 r min to 18000 r min the indicator light can be set in increments of 200 r min 1 Push the RESET button to select the desired engine speed for activating the indicator light 2 Push the SELECT button to confirm the selected engine speed The control mode changes to the shift timing...

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

Page 23: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at ...

Page 24: ...refer to the list 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 34 8 83 8 84 8 85 8 89 8 90 8 91 8 92 8 93 8 94 8 95 8 96 8 97 8 98 8 99 8 100 8 101 Valve lapper 90890 04101 Valve l...

Page 25: ... 3 13 Oil pressure adapter H 90890 03139 3 13 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 28 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 Tool name Tool No Illustration Reference pages ...

Page 26: ...437 Universal damping rod bleeding tool set YM A8703 4 51 4 52 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 51 4 52 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 57 Ring nut wrench 90890 01507 4 65 4 67 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 ...

Page 27: ...chment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 19 5 24 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 21 Valve guide installer 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 Tool name Tool No Illustration Reference pages ...

Page 28: ...1404 Flywheel puller YM 01404 5 27 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 28 5 30 5 55 6 11 Universal clutch holder 90890 04086 YM 91042 5 40 5 44 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 5 41 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 ...

Page 29: ...diator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 2 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 2 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 12 Tool name Tool No Illustration Reference pages YU 01304 YU 24460 01 YU 33984 ...

Page 30: ...ter 90890 03176 YM 03176 7 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 13 7 14 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 92 Tool name Tool No Illustration Reference pages ...

Page 31: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 25 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING 2 45 ...

Page 32: ...ifornia Dimensions Overall length 2040 mm 80 3 in Overall width 705 mm 27 8 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 188 kg 414 lb Maximum load 187 kg 412 lb ...

Page 33: ...ment 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 20 L 0 21 US qt 0 18 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 Formed Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm less than 0 0047 in L...

Page 34: ... 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 8842 0 8847 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 080 mm 0 0032 in Camshaft lobe dimensions Intake A 33 725 33 875 mm 1 3278 1 3337 in ...

Page 35: ...aust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in Valve margin thickness D intake 0 90 1 10 mm 0 0354 0 0433 in Limit 0 8 mm 0 03 in Valve margin thickness D exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 0 mm 0 04 in Valve stem diameter intake 4 475 4 490 mm 0 1762 0 1768 in Limit 4 460 mm 0 1756 in Valve stem diameter exhaust 4 460 4 475 mm 0 1756 0 1762 in Limit 4 445 mm 0 1750 in Valve gu...

Page 36: ... N mm 299 20 lb in 5 34 kgf mm Spring rate K1 exhaust 36 36 N mm 207 62 lb in 3 71 kgf mm Spring rate K2 exhaust 53 40 N mm 304 91 lb in 5 45 kgf mm Installed compression spring force intake 166 00 190 00 N 37 32 42 71 lbf 16 93 19 37 kgf Installed compression spring force exhaust 165 00 189 00 N 37 09 42 49 lbf 16 83 19 27 kgf Spring tilt intake 2 5 1 6 mm Spring tilt exhaust 2 5 1 6 mm Winding d...

Page 37: ...0 030 0 065 mm 0 0012 0 0026 in 2nd ring Ring type Taper Dimensions B T 0 80 2 50 mm 0 03 0 10 in End gap installed 0 70 0 80 mm 0 0276 0 0315 in Limit 1 15 mm 0 0453 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Oil ring Dimensions B T 1 50 2 00 mm 0 06 0 08 in End gap installed 0 10 0 35 mm 0 0039 0 0138 in Connecting rod Oil clearance using plastigauge 0 037 0 061 mm 0 0015 0 0024 in B...

Page 38: ...m 2 13 in Spring quantity 6 pcs Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 85 41 2 073 Secondary reduction system Chain drive Secondary reduction ratio 45 16 2 813 Operation Left foot operation Gear ratio 1st 31 12 2 583 2nd 32 16 2 000 3rd 30 18 1 667 4th 26 18 1 444 5th 27 21 1 286 6th 23 20 1 150 Main axle runout limit 0 02 mm...

Page 39: ...or resistance 248 372 Ω at 20 C 68 F Cylinder identification sensor output voltage ON Less than 0 8 V Cylinder identification sensor output voltage OFF More than 4 8 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 ...

Page 40: ...NLOP Qualifier PT M Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model DUNLOP Qualifier PT M Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 187 kg 198 412 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42...

Page 41: ...aster cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 10 mm 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 25 0 Center to lock angle right 25 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 115 0 mm 4 53 in Fork spring free length 254 0 mm 10 00 in Limi...

Page 42: ...88 13 lb in 10 50 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 174 1 psi 12 0 kgf cm Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9 Rebound damping adjusting positions Minimum 20 Standard 16 Maximum 3 Drive chain Type manufacturer 525V8 DAIDO Link quantity 114 Drive chain slack 30 0 45 0 mm 1 18 1 77 in 15 l...

Page 43: ... 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 Withstand voltage 200 0 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Manufacturer GS YUASA Ten hour rate amperage 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 0 W 2 Tail brake light LED F...

Page 44: ...IKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω at 20 C 68 F Performance 105 113 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Built in self canceling device No Turn signal blinking frequency 75 0 95 0 cycles min Wattage 21 23 27 W 2 0 3 4 W Oil level gauge Model manufacturer 5VX SOMIC ISHIKAWA Fuel gauge Model manufacturer 4C8 DENSO Sender unit resist...

Page 45: ... MATSUSHITA Fuses Main fuse 50 0 A Headlight fuse 15 0 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 ...

Page 46: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents 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 47: ... rod nut final M7 8 Specified angle 175 185 See NOTE Generator rotor bolt M12 1 70 Nm 7 0 m kg 52 ft lb Timing chain tensioner bolt M6 2 12 Nm 1 2 m kg 8 9 ft lb Thermostat cover bolt M6 2 12 Nm 1 2 m kg 8 9 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 4 ft lb Water pump assembly bolt M6 2 12 Nm 1 2 m kg 8 9 ft lb Water pump housing cover bolt M6 2 10 Nm 1 0 m kg 7 4 ft lb Oil pump assembly...

Page 48: ...7 Nm 0 7 m kg 5 2 ft lb Crankcase bolt M8 2 See NOTE l 115 mm 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 18 ft lb l 65 mm 2 56 in Crankcase bolt M6 16 10 Nm 1 0 m kg 7 4 ft lb Generator cover bolt M6 9 12 Nm 1 2 m kg 8 9 ft lb Clutch cover bolt M6 7 12 Nm 1 2 m kg 8 9 ft lb Clutch cover bolt M6 2 12 Nm 1 2 m kg 8 9 ft lb Pickup rotor cover bolt M6 7 12 ...

Page 49: ... M6 6 8 Nm 0 8 m kg 5 9 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 63 ft lb Stake Main axle screw M6 3 12 Nm 1 2 m kg 8 9 ft lb Stake Shift drum retainer bolt M6 2 10 Nm 1 0 m kg 7 4 ft lb Shift shaft spring stopper M8 1 22 Nm 2 2 m kg 16 ft lb Shift arm bolt M6 1 10 Nm 1 0 m kg 7 4 ft...

Page 50: ...TIGHTENING TORQUES 2 19 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 51: ...m kg 3 7 ft lb Front brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 2 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 20 ft lb Rear brake pad pin M10 1 17 Nm 1 7 m kg 13 ft lb Rear brake screw plug 1 2 Nm 0 2 m kg 1 5 ft lb Handlebar pinch bolt M8 2 32 Nm 3 2 m kg 24 ft lb Handlebar bolt M...

Page 52: ... 12 ft lb Swingarm pivot shaft ring nut M32 1 95 Nm 9 5 m kg 70 ft lb Swingarm pivot shaft nut M22 1 70 Nm 7 0 m kg 52 ft lb Drive chain guide swingarm side bolt M6 1 7 Nm 0 7 m kg 5 2 ft lb Drive chain guard bolt M6 1 7 Nm 0 7 m kg 5 2 ft lb Drive chain adjusting locknut M8 2 16 Nm 1 6 m kg 12 ft lb Drive chain adjusting bolt M8 2 2 Nm 0 2 m kg 1 5 ft lb Rear fender bolt M6 3 7 Nm 0 7 m kg 5 2 ft...

Page 53: ... 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening Front cowling assembly bolt M6 4 13 Nm 1 3 m kg 9 6 ft lb Seat lock assembly bolt M6 2 7 Nm 0 7 m kg 5 2 ft lb Rider seat and frame M6 2 7 Nm 0 7 m kg 5 2 ft lb Battery box and frame M6 2 4 Nm 0 4 m kg 3 0 ft lb Rear upper cowling damper plate and frame M6 4 7 Nm 0 7 m kg 5 2 ft lb License plate li...

Page 54: ...m 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 pinch bolt 2 ...

Page 55: ...and oil pump housing Oil strainer screen inside oil strainer Oil strainer seal Oil cooler bolt 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 boss nut Clutch pull rod Transmission gears wheel and pinion and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Cy...

Page 56: ...ber spacer Swingarm pivot shaft Swingarm pivot shaft bearings 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...

Page 57: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 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 59: ...ND DIAGRAMS 2 28 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 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Ventilation chamber cover 2 Relief valve 3 Ventilation chamber oil drain pipe 4 Oil cooler ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 1 2 3 4 8 7 6 5 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 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 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2 3 4 5 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil cooler 2 Oil filter 3 Oil pipe 4 Oil pump 5 Oil strainer ...

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

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil pump 3 Oil pipe 4 Ventilation chamber oil drain pipe 5 Relief valve ...

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

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil nozzle ...

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

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil pipe 2 Main axle 3 Drive axle ...

Page 72: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 ...

Page 73: ...COOLING SYSTEM DIAGRAMS 2 42 1 Radiator inlet hose 2 Radiator inlet pipe 3 Thermostat outlet hose 4 Radiator ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 43 A A 2 1 3 4 5 6 7 8 6 13 8 9 15 14 9 10 11 12 ...

Page 75: ... 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 76: ...CABLE ROUTING 2 45 EAS20430 CABLE ROUTING ...

Page 77: ...locking tie above where the horn leads branch off from the other leads C Set the front brake hose in front of the vehi cle and outward and secure it between 2 22 degrees angle Direct the tip of the plas tic locking tie to outer side of the vehicle and cut it by leaving the tip 2 4 mm 0 08 0 16 in D 20 30 mm 0 79 1 18 in E Route the right handlebar switch lead between the front brake master cylinde...

Page 78: ...CABLE ROUTING 2 47 60 20 AA BB CC E E B D D B A A C C C ...

Page 79: ... O2 sensor lead between the top and bottom plastic locking ties are not twisted or crossed J Clamp the EXUP servo motor lead EXUP cable rear brake light switch lead and O2 sensor Clamp position should be above the EXUP cable holder and within 20mm 0 79 in from the bottom of the EXUP cable holder Face the tip of the plastic locking tie to back of the vehicle and cut off the excess end of the plasti...

Page 80: ...CABLE ROUTING 2 49 ...

Page 81: ...eather hose should be below the engine clamp G 30 50 mm 1 18 1 97 in H Route the fuel tank drain hose and fuel tank breather hose through the guide of the sidestand bracket cover Route the side stand switch lead from between the guides to inside of the hose I Route the AC magneto lead between the frame and throttle body and under the hose J After connecting the connector of the AC magneto lead put...

Page 82: ...CABLE ROUTING 2 51 ...

Page 83: ... motor lead through the inside of the main harness There is no order for placing the throttle position sensor lead and throttle servo motor lead J To the engine K To the throttle body L To the coolant temperature sensor M Route the coolant temperature sensor lead above the pickup coil lead neutral switch lead oil level switch lead and speed sensor lead N Push the throttle body lead inward and plac...

Page 84: ...CABLE ROUTING 2 53 ...

Page 85: ...e from upper part of the frame and direct the remaining part of the tip toward inner side of the vehicle AB Route the sub wire harness secondary injector through the area shown in the illustration Insert the plastic locking tie from upper part of the frame and direct the remaining part of the tip toward inner side of the vehicle ...

Page 86: ...CABLE ROUTING 2 55 ...

Page 87: ... 5 Headlight lead high beam 6 Air temperature sensor lead 7 Atmospheric pressure sensor lead A Secure the headlight sub wire harness with the air duct hook B To the headlight relay on off C Clamp the white tape part on the headlight sub wire harness D Clamp the white tape part only on the lead connecting to the headlight relay dimmer ...

Page 88: ...CABLE ROUTING 2 57 ...

Page 89: ...ht lead right rear turn signal light lead license plate light lead and tail brake light lead with a clamp D Make sure to hook the main harness case to the tab on the battery box assembly Be careful not to pinch the leads E When securing each lead with the plastic locking tie the leads should not touch the ECU engine control unit Face the end of the plastic locking tie downward There is no order fo...

Page 90: ...CABLE ROUTING 2 59 A A ...

Page 91: ...CABLE ROUTING 2 60 1 Fuel tank breather hose Except for Califor nia 2 Fuel tank drain hose 3 Main harness 4 Fuel hoses 5 Fuel tank breather hose Except for Califor nia 6 Fuel tank drain hose 7 Clamp ...

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

Page 93: ...6 ADJUSTING THE EXUP CABLES 3 17 CHECKING THE COOLANT LEVEL 3 18 CHECKING THE COOLING SYSTEM 3 19 CHANGING THE COOLANT 3 19 CHASSIS 3 22 ADJUSTING THE FRONT DISC BRAKE 3 22 ADJUSTING THE REAR DISC BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL 3 23 CHECKING THE FRONT BRAKE PADS 3 23 CHECKING THE REAR BRAKE PADS 3 23 CHECKING THE FRONT BRAKE HOSES 3 24 CHECKING THE REAR BRAKE HOSES 3 24 ADJUSTING THE RE...

Page 94: ...LUBRICATING THE REAR SUSPENSION 3 35 ELECTRICAL SYSTEM 3 36 CHECKING AND CHARGING THE BATTERY 3 36 CHECKING THE FUSES 3 36 REPLACING THE HEADLIGHT BULBS 3 36 ADJUSTING THE HEADLIGHT BEAMS 3 36 ...

Page 95: ......

Page 96: ... Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhaust system Check for leakage Tighten if necessary Replace gasket s if ...

Page 97: ... Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease lightly 17 Sidestand pivot Check operation Apply lithium soap based g...

Page 98: ...ery two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene glycol antifreeze coolant every 24 months Change 25 Front and rear brake switches Check operation 26 Control cables Apply Ya...

Page 99: ...OTTLE BODIES on page 7 9 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 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 ...

Page 100: ...e a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 NOTE Cover 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 installed in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example...

Page 101: ... 1 and the valve lifter 2 NOTE Lubricate the valve lifter with engine oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts timing 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 ...

Page 102: ... a white paint mark out a little and then turn it in fully c Using the throttle body that has the bypass air screw with a white paint mark as the standard turn the bypass air screws with out 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 standar...

Page 103: ...een two throttle bodies should not exceed 1 33 kPa 10 mmHg 7 Stop the engine and remove the measuring equipment 8 Allow the engine to cool and then start the engine and check that the engine speed does not rise abnormally high 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 8 10 Install Caps Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GE...

Page 104: ... falling into the cylinders 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plugs Ignition coils NOTE Before ...

Page 105: ...ng ground all spark plug leads before cranking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a ...

Page 106: ...oil level CAUTION EC2C01005 Since engine oil also lubricates the clutch the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERVING II b Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several minutes and then turn it o...

Page 107: ... 1 of the new oil filter cartridge with a thin coat of engine oil CAUTION EC2C01006 Make sure the O ring 1 is positioned cor rectly in the groove of the oil filter car tridge e Tighten the new oil filter cartridge to speci fication with an oil filter wrench f Insert the fuel tank breather hose and fuel tank overflow hose into the guide and place them in their original position g Install the shift ...

Page 108: ... higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Side cowling assembly Refer to GENERAL CHASSIS on page 4 1 4 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are extremely hot 5 Install Oil pressure gauge set 1 Oil pressure adapter H 2 6 Measure Engine oil pressure a...

Page 109: ...d clutch lever free play is obtained c Tighten the locknut 1 EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Upper air filter case Refer to AIR FILTER CASE on page 7 4 2 Remove Air filter element 1 Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage...

Page 110: ...will also affect the throttle body synchronization leading to poor engine performance and possible overheating NOTE When installing the air filter element into the lower air filter case make sure that the sealing surfaces are aligned to prevent any air leaks 5 Install Upper 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 CHA...

Page 111: ...to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly CAUTION ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tan...

Page 112: ...ic 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 prop erly NOTE Check that the projection a on the EXUP valve pulley contacts the stopper b fully open Exhaust pipe assembly and cyl inder head nut 20 Nm 2 0 m kg 15 ft lb Exhaust pipe assembly bracket left upper side and right side and frame bolt 30 Nm 3 0 m kg 22 ft l...

Page 113: ...ble stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Remove the coolant reservoir cap add 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 pulle...

Page 114: ...ING THE COOLING SYSTEM 1 Remove Side cowling assembly 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 outlet hose 5 Radiator outlet pipe 6 Oil cooler 7 Oil cooler outlet hose 8 Oil cooler inlet hose 9 Water pump outlet hose 10 Water pump inlet hose Water p...

Page 115: ...tor 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 Handling notes for coolant Coolant is potentially harmful and should be handled with special ...

Page 116: ...ater is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maximum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for several minutes and then stop it 16 Check Coolant leve...

Page 117: ...e 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 can indicate the presence of air in the brake system ...

Page 118: ... 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 reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRO...

Page 119: ...ply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 30 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operatio...

Page 120: ... fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the 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 a...

Page 121: ...n 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 swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no d...

Page 122: ...ning high pressure washing certain sol vents and the use of a coarse brush can dam age 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 sol vents that could damage the O rings EAS21500 ...

Page 123: ...D on page 4 55 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary 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 HE...

Page 124: ...oseness Adjust the steering head EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING 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 time...

Page 125: ...the maximum or minimum adjustment positions 1 Adjust Compression damping fast compression damping Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 0 Standard 2 Maximum 5 1 Adjusting bolt 1 a b 3 1 2 4 0 5 1 3 2 2 Current setting 3 Cap bolt collar Direction a turn in Rebound damping ...

Page 126: ...ing with the position indicator 2 Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression damping adjusting positions fast compression damping Minimum 4 turn s in direction b Standard 2 turn s in direction b Maximum 0 turn s in direction b With the adjusting bolt fully turned in Direction a turn in Compression ...

Page 127: ...irection a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 20 click s out Standard 16 click s out Maximum 3 click s out With the adjusting screw fully turned in 1 a b 2 Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping...

Page 128: ...e damage an accident or an injury NEVER OVERLOAD THE VEHICLE 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 20 click s out Standard 16 click s out Maximum 1 click s out With the adjusting screw fully turned in a b 1 Tire air ...

Page 129: ...y replacement WARNING EWA14090 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufac turer and of the same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi cle WARNING EWA13210 New tires have a...

Page 130: ... as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable 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 ...

Page 131: ...ed down 5 Install Headlight bulb Secure the new headlight bulb with the headlight 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 132: ... 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 133: ...ISC 4 16 FRONT BRAKE 4 18 INTRODUCTION 4 23 CHECKING THE FRONT BRAKE DISCS 4 23 REPLACING THE FRONT BRAKE PADS 4 24 REMOVING THE FRONT BRAKE CALIPERS 4 25 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 25 CHECKING THE FRONT BRAKE CALIPERS 4 26 ASSEMBLING THE FRONT BRAKE CALIPERS 4 26 INSTALLING THE FRONT BRAKE CALIPERS 4 26 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT BRAKE MASTER CY...

Page 134: ...NSTALLING THE STEERING HEAD 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 59 HANDLING THE REAR SHOCK ABSORBER 4 60 DISPOSING OF A REAR SHOCK ABSORBER 4 60 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 60 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE CONNECTING ARM AND RELAY ARM 4 61 INSTALLING THE RELAY ARM 4 61 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 SWINGARM 4 63 REMOVING THE SWINGARM...

Page 135: ......

Page 136: ... battery Order Job Parts to remove Q ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Fuel tank bracket 1 4 Battery negative lead 1 Disconnect 5 Battery positive lead 1 Disconnect 6 Battery band 1 7 Battery 1 For installation reverse the removal proce dure 1 7 5 6 4 2 3 ...

Page 137: ...er 1 3 Rear upper cowling 1 4 Rear upper cowling damper plate 1 5 Seat lock assembly 1 6 Tail brake light coupler 1 Disconnect 7 Rear turn signal light coupler 2 Disconnect 8 License plate light connector 2 Disconnect 9 ECU coupler 2 Disconnect 10 ECU engine control unit 1 11 Turn signal light relay coupler 1 Disconnect 12 Lean angle sensor coupler 1 Disconnect 13 Starting circuit cut off relay co...

Page 138: ...is registered for only a solo rider 19 License plate light assembly 1 20 Rear lower cowling assembly 1 21 Tail brake light assembly 1 22 Rear lower cowling 1 23 Tail brake light cover 1 For installation reverse the removal proce dure Removing the tail brake light assembly Order Job Parts to remove Q ty Remarks ...

Page 139: ... light coupler 2 Disconnect 4 Middle side cowling 2 5 Air intake duct 2 6 Front turn signal light bracket 2 7 Front turn signal light 2 8 Bottom cowling 2 9 Upper side cowling 2 10 Bottom cowling inner panel 2 11 Rear view mirror 2 12 Windshield 1 13 Headlight sub wire harness coupler 3 Disconnect 14 Front cowling assembly 1 For installation reverse the removal proce dure ...

Page 140: ...onnect 4 Atmospheric pressure sensor coupler 1 Disconnect 5 Meter assembly 1 6 Meter bracket 1 7 Air duct 1 8 Air temperature sensor 1 9 Atmospheric pressure sensor 1 10 Headlight relay coupler 2 Disconnect 11 Headlight coupler 2 Disconnect 12 Headlight sub wire harness 1 13 Headlight relay 2 14 Headlight assembly 1 15 Front cowling 1 For installation reverse the removal proce dure ...

Page 141: ...ght reflector assembly 1 3 Left front brake hose holder 1 4 Right front brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 Loosen 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Front wheel 1 11 Collar 2 12 Dust cover 2 13 Front brake disc 2 For installation reverse the removal proce dure ...

Page 142: ...FRONT WHEEL 4 7 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 143: ...heel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral 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 axle 2 Check Tir...

Page 144: ...T WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Tu...

Page 145: ...eel does not remain station ary at all of the positions rebalance it ET2C01002 CHECKING THE FRONT BRAKE DISCS Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 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...

Page 146: ... tem porary tightening c Check that the right 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...

Page 147: ...aliper 1 2 Drive chain adjusting locknut 2 Loosen 3 Drive chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Rear wheel axle 1 6 Rear wheel 1 7 Rear brake caliper bracket 1 For installation reverse the removal proce dure S S T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 20 ft Ib T R 110 Nm 11 0 m kg 81 ft Ib ...

Page 148: ...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 149: ...REAR WHEEL 4 14 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 150: ... WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 35 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 ET2C01024 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake...

Page 151: ...the 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 9 ET2C01004 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 35 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in ...

Page 152: ...E CHAIN SLACK on page 3 26 5 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed prop erly Drive chain slack 30 0 45 0 mm 1 18 1 77 in Rear brake caliper bolt M12 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE ...

Page 153: ...to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Reflector assembly 1 2 Brake hose holder 1 3 Front brake caliper 1 4 Brake pad clip 2 5 Brake pad pin 1 6 Brake pad spring 1 7 Front brake pad 2 For installation reverse the removal proce dure ...

Page 154: ...eservoir diaphragm holder 1 4 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 ...

Page 155: ...embling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 3 2 1 New New BF BF ...

Page 156: ...ure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Reflector assembly 1 2 Brake hose holder 1 3 Front brake hose union bolt 1 4 Copper washer 2 5 Front brake hose 1 6 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 157: ...wing 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 4 7 Brake caliper piston dust seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure BF S S BF BF BF ...

Page 158: ...CS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 6 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the ...

Page 159: ...of specification Replace the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Ins...

Page 160: ...emove Front brake hose union bolt 1 Copper washers 2 Front brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 Brake caliper piston dust seals 3 WARNING EWA13S1001 Do not loose...

Page 161: ...ned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals and brake caliper piston dust seals EAS22450 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake calipers 1 Install Front brake...

Page 162: ...r Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid ...

Page 163: ...KE MASTER CYLINDER 1 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 2 Install Front brake hose 1 Copper washers 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essent...

Page 164: ... 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 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 5 Check Brake fluid level Below the minimum level mark a A...

Page 165: ...ear 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 4 7 5 S S S ...

Page 166: ...eservoir 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir hose 1 6 Rear brake hose 1 7 Right footrest assembly 1 8 Rear brake light switch 1 9 Footrest plate 1 10 Rear brake master cylinder 1 11 Brake fluid reservoir bracket 1 For installation reverse the removal proce dure 1 2 3 4 6 8 9 10 7 5 New 11 ...

Page 167: ...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 2 1 3 BF ...

Page 168: ...r Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure S S ...

Page 169: ...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 1 9 Brake caliper piston dust seal 1 10 Bleed screw 1 For assembly reverse the disassembly pro cedure S S BF ...

Page 170: ...lling 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 23 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 5 Adjust Brake disc deflection Refer to CHECK...

Page 171: ...roper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake...

Page 172: ...y passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13S1004 Whenever a brake caliper is disassembled replace the brake caliper piston seal and brake caliper piston dust seal 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13S1005 Before installation all internal brake com ponents should be cleaned and lubrica...

Page 173: ...akage 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 perfor mance 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 flu...

Page 174: ...damage Replace Brake fluid reservoir diaphragm Cracks damage 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 components EAS22740 INSTALLING THE...

Page 175: ...apor 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 25 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 23 5 Check Brake ...

Page 176: ... Refer to AIR INDUCTION SYSTEM on page 7 15 1 Left grip end 1 2 Handlebar grip 1 3 Clutch 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 12 Right handlebar switch Bracket 1 1 13 Front brake m...

Page 177: ... coupler holder 1 17 Main switch coupler 2 Disconnect 18 Upper bracket 1 19 Left handlebar 1 20 Right handlebar 1 For installation reverse the removal proce dure Removing the handlebars Order Job Parts to remove Q ty Remarks ...

Page 178: ...surface WARNING EWA13120 Securely 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 3 Install Right handlebar switch 1 Right handle...

Page 179: ...ar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clearance a between the handlebar grip and the grip end 9 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer...

Page 180: ...ont fork legs Side panels Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 6 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 4 5 7 1 3 6 2 ...

Page 181: ...Cap bolt 1 2 O ring 1 3 Washer 1 4 Damper adjusting rod 1 5 Nut 1 6 Spacer 1 7 Upper spring seat 1 8 Fork spring 1 9 Under spring seat 1 10 Outer tube 1 11 Dust seal 1 12 Oil seal clip 1 13 Oil seal 1 14 Washer 1 15 Damper rod assembly 1 16 Inner tube 1 For assembly reverse the disassembly pro cedure 1 2 New 3 5 6 8 7 9 10 14 13 12 11 New New New 4 15 16 ...

Page 182: ...ING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Position the collar 1 as shown in the illus tration by turning the spring preload adjust ing 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 ...

Page 183: ...asher 5 Remove Damper rod assembly NOTE Remove the damper rod assembly with the damper rod holder 1 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 sp...

Page 184: ...oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to slide...

Page 185: ... bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Washer Oil seal 1 with the fork seal driver 2 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 ...

Page 186: ...k oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any resid ual 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 Under spring seat 1 Fork sp...

Page 187: ...ide of the rod holder that is marked B j Remove the rod puller and rod puller attachment k Install the nut 4 all the way onto the damper rod assembly l Install the damper adjusting rod m Install the washer and cap bolt and then finger tighten the cap bolt n Hold the nut and tighten the spring preload adjusting bolt 10 into the cap bolt to spec ification 6 1 2 4 3 5 7 8 Rod puller 90890 01437 Unive...

Page 188: ...s 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 tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 and 2 NOTE 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 pinch bolt 2 3 Tighten Cap bol...

Page 189: ... on page 2 45 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 29 1 2 ...

Page 190: ...ARS on page 4 41 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 4 Air induction system cover Refer to AIR INDUCTION SYSTEM on page 7 15 1 Front brake hose joint 1 2 Horn 1 3 Front brake hose joint bracket 1 4 Lower bracket cover 1 5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Throttle cable guide 1 11 Upper...

Page 191: ...er bearing 1 15 Lower bearing inner race 1 16 Lower bearing dust seal 1 17 Upper bearing outer race 1 18 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 192: ...tting Replace 3 Replace Bearings Bearing races a Remove the bearing race from the steering head pipe 1 with a long rod 2 and ham mer 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 ...

Page 193: ...h bolts 5 Tighten Steering stem nut 6 Install Front brake hose joint bracket 1 Lower bracket cover 2 Front brake hose joint 3 NOTE Route the right brake pipe a through the pro jections b of the front brake hose joint bracket 7 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on pag...

Page 194: ...brackets Refer to ENGINE REMOVAL on page 5 1 Rear wheel Refer to REAR WHEEL on page 4 12 Fuel tank Refer to FUEL TANK on page 7 1 1 Connecting arm 2 2 Relay arm collar 1 3 Relay arm 1 4 Collar 1 5 Collar 1 6 Oil seal 6 7 Bearing 2 8 Bearing 2 9 Washer 1 10 Rear shock absorber assembly bracket 1 11 Rear shock absorber assembly 1 For installation reverse the removal proce dure ...

Page 195: ...d before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in 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...

Page 196: ...g Replace 3 Check Collars Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Collars Bearings 2 Install Bearings 1 2 to the relay arm Oil seals 3 EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Collar Bearings 2 Tighten Relay arm nut 3 Install Rear shock absorber assembly Washer 1 Rear shock absorber assembly bracket 2 Spacer bolt 3 Recommended lubricant Lithiu...

Page 197: ...ut Rear shock absorber assembly bracket nut 5 Install Connecting arms NOTE When installing the connecting arms lift up the swingarm 6 Tighten Connecting arm nuts Spacer bolt 16 Nm 1 6 m kg 12 ft lb Rear shock absorber assembly lower nut 40 Nm 4 0 m kg 30 ft lb Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 33 ft lb Rear shock absorber assembly bracket nut 52 Nm 5 2 m kg 38 ft lb Connecting ...

Page 198: ...RIVE on page 4 68 1 Drive chain adjusting locknut 2 2 Drive chain puller 2 3 Drive chain adjusting bolt 2 4 Rear fender 1 5 Left footrest assembly 1 6 Drive chain guard 1 7 Drive chain guide swingarm side 1 8 Drive chain 1 9 Swingarm pivot shaft nut 1 10 Washer 1 11 Swingarm pivot shaft ring nut 1 12 Washer 1 13 Swingarm pivot shaft 1 14 Swingarm 1 15 Dust cover 2 4 17 10 15 15 21 14 16 20 18 5 7 ...

Page 199: ...r 1 19 Collar 1 20 Oil seal 2 21 Bearing 2 For installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 4 17 10 15 15 21 14 16 20 18 5 7 6 3 11 13 9 3 2 19 12 1 1 2 LS LS 21 20 8 LS LS New New LS LS LS ...

Page 200: ... down If swingarm vertical movement is not smooth or if there is binding check the col lars bearings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 69 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 damper rod hold...

Page 201: ...earings 3 Oil seals 4 3 Install Swingarm pivot shaft 1 NOTE Tighten the swingarm pivot shaft with the damper rod holder 24 mm 2 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 s...

Page 202: ... 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 26 Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 70 ft lb Ring nut wrench 90890 01507 Swingarm pivot shaft nut 70 Nm 7 0 m kg 52 ft lb 2 1 2 1 Drive chain slack 30 0 45 0 ...

Page 203: ...NERAL CHASSIS on page 4 1 Left bottom 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 sprocket 1 5 Drive chain 1 6 Drive chain guide drive sprocket side 1 For installation reverse the removal proce dure New 1 4 6 3 2 5 T R 10 Nm 1 0 m kg 7 4 ft Ib ...

Page 204: ...ink section length c length a between pin inner sides 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 differ ent 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...

Page 205: ... CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 15 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Stake the drive...

Page 206: ...CHAIN DRIVE 4 71 1 2 3 a a New ...

Page 207: ...CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 23 CHECKING THE VALVE LIFTERS 5 24 INSTALLING THE VALVES 5 24 GENERATOR AND STARTER CLUTCH 5 26 REMOVING THE GENERATOR 5 27 CHECKING THE STARTER CLUTCH 5 27 INSTALLING THE STARTER CLUTCH 5 27 INSTALLING THE GENERATOR 5 28 PICKUP ROTOR 5 29 REMOVING THE PICKUP ROTOR 5 30 INSTALLING THE PICKUP ROTOR 5 30 ELECTRIC STARTER 5 32 CHECKING THE ST...

Page 208: ...SE 5 55 CHECKING THE CRANKCASE 5 55 CHECKING THE OIL PIPE 5 55 CHECKING THE TIMING CHAIN 5 55 ASSEMBLING THE CRANKCASE 5 55 CONNECTING RODS AND PISTONS 5 57 REMOVING THE CONNECTING RODS AND PISTONS 5 58 CHECKING THE CYLINDERS AND PISTONS 5 58 CHECKING THE PISTON RINGS 5 59 CHECKING THE PISTON PINS 5 60 CHECKING THE CONNECTING RODS 5 61 INSTALLING THE CONNECTING RODS AND PISTONS 5 62 CRANKSHAFT 5 6...

Page 209: ......

Page 210: ...t pipe assembly 1 10 Gasket 4 11 Exhaust pipe assembly bracket left lower side 1 12 Exhaust pipe assembly bracket left upper side 1 13 Exhaust pipe assembly bracket right side 1 14 EXUP servo motor assembly 1 15 EXUP servo motor bracket 1 LS LT 12 10 1 2 3 5 4 6 8 7 9 New LT T R 20 Nm 2 0 m kg 15 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib New T R 7 Nm 0 7 m kg 5 2 ft Ib T R 8 Nm...

Page 211: ...Q ty Remarks LS LT 12 10 1 2 3 5 4 6 8 7 9 New LT T R 20 Nm 2 0 m kg 15 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib New T R 7 Nm 0 7 m kg 5 2 ft Ib T R 8 Nm 0 8 m kg 5 9 ft Ib T R 8 Nm 0 8 m kg 5 9 ft Ib T R 45 Nm 4 5 m kg 33 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 34 Nm 3 4 m kg 25 ft Ib LT LT T R 7 Nm 0 7 m kg 5 2 ft Ib 13 16 17 14 15 18 3 2 T R 6 Nm 0 6 m kg 4 4 ft Ib 11 T R 10 ...

Page 212: ...l cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 8 Drive sprocket Refer to CHAIN DRIVE on page 4 68 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 7 Engine ground terminal 1 Disconnect 8 Oil level switch coupler 1 Disconnect 9 Crankshaft position sensor coupler ...

Page 213: ... 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 4 ft Ib T R 10 Nm 1 0 m kg 7 4 ft Ib T R 7 Nm 0 7 m kg 5 2 ft Ib T R 10 Nm 1 0 m kg 7 4 ft Ib New New LS T R 70 Nm 7 0 m kg 52 ft lb LS T R 17 Nm 1 7 m kg 13 ft Ib ...

Page 214: ...g collar outside 1 8 Engine mounting collar center 1 9 Engine mounting collar inside 1 10 Engine mounting bolt rear upper side 1 11 Engine mounting nut rear lower side 1 12 Engine mounting collar outside 1 13 Engine mounting collar center 1 14 Engine mounting collar inside 1 15 Engine mounting bolt rear lower side 1 16 Engine 1 For installation reverse the removal proce dure 1 2 3 4 4 11 12 13 6 8...

Page 215: ...arily tighten NOTE Be sure to pass 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 7 Engine mounting nut rear upper side 8 Engine mounting bolts front left side 9 Engine mounting bolts front right side 13 3 Install Shift arm 1 NOTE Install the shift arm 1 with its punch mark a aligned with the...

Page 216: ...r cut off valve Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 15 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 5 New New LT LT LS T R 8 Nm 0 8 m kg 5 9 ft Ib T R 13 Nm 1 3 m kg 9 6 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib ...

Page 217: ...ner 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 4 ft Ib T R 10 Nm 1 0 m kg 7 4 ft Ib T R 24 Nm 2 4 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib New 4 1 6 2 3 10 9 7 5 5 5 8 6 ...

Page 218: ...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 219: ...a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge 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 Limit 32 875 mm 1 2943 in Exhau...

Page 220: ...ide Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TEN SIONER 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 ...

Page 221: ...ip while pushing the rod into the housing other wise the rod may be ejected c Hook the clip 4 to the timing chain ten sioner 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 ...

Page 222: ... each cam shaft points towards the right side of the engine 4 Install Camshaft cap bolts CAUTION ECA13730 The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft 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 NO...

Page 223: ...ark 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 cylinder 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 CLEARANCE on page 3 4 10 Install Cylinder head cover gaske...

Page 224: ... head Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Camshafts Refer to CAMSHAFTS 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 ...

Page 225: ...alves with the cylinder head Refer to CHECKING THE VALVE SEATS on page 5 21 Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder 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 cylin der head as follows d Place a 400 600 gr...

Page 226: ...head nuts cap nuts and bolts in the proper tightening sequence as shown and torque them in two stages Cylinder head nut 1st 25 Nm 2 5 m kg 18 ft lb Cylinder head nut final 42 Nm 4 2 m kg 31 ft lb 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 44 ft lb Cylinder head bolt 12 Nm 1 2 m kg 8 9 ft lb 8 6 2 4 10 9 3 1 5 7 12 11 ...

Page 227: ...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 228: ...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 attach ment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring ...

Page 229: ...alve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 m...

Page 230: ... valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylin der head 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 04117 Valve guide reamer ø4 5 90...

Page 231: ...ve faces When replacing the valves or valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve ...

Page 232: ...e the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the 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 Installed compression spring force intake 166 00 190 00 N 37 32 42 71 lbf 16 93 19 37 kgf Installe...

Page 233: ...ed lubricant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compre...

Page 234: ...CA13800 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 rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Engine oil ...

Page 235: ...4 1 Engine oil Drain Refer to CHANGING THE ENGINE 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 11 Starter clutch gear 1 For installation reverse the removal ...

Page 236: ...ch 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 generator 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 s...

Page 237: ... 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 grom met Generator rotor bolt 70 Nm 7 0 m kg 52 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A a 1 New 1 2 3 Yamaha bond No 1215 90890 8...

Page 238: ...TOR 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 5 4 2 6 LS New New New T R 10 Nm 1 0 m kg 7 4 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg...

Page 239: ...pickup 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 Pickup coil rotor bolt 35 Nm 3 5 m kg 26 ft lb Sheav...

Page 240: ...PICKUP ROTOR 5 31 ...

Page 241: ...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 6 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 4 ft Ib ...

Page 242: ... 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 T R 7 Nm 0 7 m kg 5 2 ft Ib ...

Page 243: ...commu tator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace 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 244: ...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 245: ... 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 T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft ...

Page 246: ... 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 247: ... 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 17 Bearing 1 18 Clutch housing 1 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E E E T R 8 Nm 0 8 m kg 5 9 ft Ib T R 25 Nm 2 5 m kg 18 ft ...

Page 248: ...de 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 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E E E T R 8 Nm 0 8 m kg 5 9 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 115 Nm 11 5 m kg 85 ft lb ...

Page 249: ...procket and then remove the clutch housing and oil pump drive chain from the main axle EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set NOTE Measure the friction plate at four places ...

Page 250: ...er 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 clutch springs as a set Thickness gauge 90890 03180 Feeler gauge set YU 269...

Page 251: ...ng on the clutch boss splines will cause erratic clutch operation EAS25170 CHECKING THE PRESSURE 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 crank shaft as a set EAS2...

Page 252: ... oil pump driven sprocket as a set EAS25270 INSTALLING THE CLUTCH 1 Install Oil pump drive chain 1 Clutch housing 2 NOTE Install the oil pump drive chain onto the clutch housing and then install 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 bos...

Page 253: ...tion plate 1 offset from the other friction plates 2 making sure to align a projection on the friction plate with the punch mark a on the clutch housing 7 Install Pressure plate 1 NOTE Align the punch marks a in the pressure 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 cr...

Page 254: ...ges and in a crisscross pattern 10 Install Pull lever spring 1 Pull lever 2 Washer Circlip NOTE Make sure that the mark a on the pull lever 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 TH...

Page 255: ...ousing Refer to CLUTCH on page 5 36 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 13 Bearing 2 For installation reverse the removal proce dure 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 256: ... wear 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 shif...

Page 257: ...h housing Refer to CLUTCH on page 5 36 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 9 Oil pipe 1 10 Ventilation chamber oil drain pipe 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 E LT T R 10 Nm 1...

Page 258: ...ure 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 E LT T R 10 Nm 1 0 m kg 7 4 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 43 Nm 4 3 m kg 32 ft Ib ...

Page 259: ... 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 260: ...g clear ance 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 housing Inne...

Page 261: ... shaft 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 inner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 51 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan...

Page 262: ...er to CLUTCH on page 5 36 Oil pump assembly Refer to OIL PUMP on page 5 48 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 9 Oil baffle plate 2 1 10 Lower crankcase 1 11 Dowel pin 3 11 4 3 2 11 6 10 1 8 9 7 5 T R 8 Nm 0 8 m kg 5 9 ft Ib T R 8 Nm 0 8 m kg 5 9ft Ib T R 12 N...

Page 263: ...arts 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 9 ft Ib T R 8 Nm 0 8 m kg 5 9ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 12 Nm 1 2 m kg 8 9 ft Ib T R 20 Nm 2 0 m kg 15 ft Ib LS New New New New New LS LS LS LT LT LT LT LT T R 12 Nm 1 2 m kg 8 9 ft Ib ...

Page 264: ...HE CRANKCASE 1 Thoroughly wash the crankcase 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 compressed air EAS25620 CHECKING THE TIMING CHAIN Refer ...

Page 265: ...6 30 mm bolt 29 7 Tighten Crankcase bolts 1 10 Loosen all bolts following the tightening order and then tighten to specification torque NOTE Lubricate the bolt threads and the bearing surfaces with engine oil Tighten the bolts in the tightening sequence cast on the crankcase 8 Tighten Crankcase bolts 11 29 NOTE Lubricate the bolt threads and the bearing surfaces with engine oil Tighten the bolts i...

Page 266: ...to CRANKCASE on page 5 53 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 267: ...eference during installation put an iden tification mark on each piston crown Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers an...

Page 268: ...G THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 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...

Page 269: ... of the piston pins 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrica tion system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the pis ton 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 60 mm 0 0236 in 2n...

Page 270: ...the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolt threads and nut ...

Page 271: ...nnecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 1 respectively then the bearing size for P1 is EAS26170 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pistons and connecting rods 1 Insta...

Page 272: ...ston Piston rings Cylinder with the recommended lubricant 5 Lubricate Bolt threads Nut seats with the recommended lubricant 6 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant 7 Install Big end bearings Connecting rod and piston assembly Connecting rod cap NOTE Align the projections on the big end bearings with the notches in the connecting rods...

Page 273: ...en the connecting rod nuts with a torque wrench b Put a mark 1 on the corner of the con necting rod nut 2 and the connecting rod 3 c Tighten the connecting rod nuts further 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 o...

Page 274: ...ks Crankcase Separate Refer to CRANKCASE on page 5 53 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 57 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 275: ... Measure 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 crankshaft journal bearings must be installed in their original positions a Clean the cran...

Page 276: ...on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the crank shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to th...

Page 277: ...pper crankcase Crankshaft journal lower bearings into the lower crankcase NOTE Align the projections a on the crankshaft journal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bearing in its original place Bearing color code 0 White 1 Blue 2 Black 3 Brown 4 Green ...

Page 278: ...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 15 Bearing 1 For installation reverse the removal proce dure 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 9 ft Ib T R 10 Nm 1 0 m kg 7 4 ft Ib E New T R...

Page 279: ... 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 280: ...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 18 2nd wheel gear 1 19 Collar 1 20 Bearing 1 21 Drive axle 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 281: ...ON 5 72 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 282: ...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 sur face 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 ...

Page 283: ...d edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmis sion axle assemblies 5 Check Transmission gear movement Rough movement Replace the defec tive 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 284: ...f the bearing to the outside 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 a...

Page 285: ... fork R into the groove 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 Shift drum retainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 2 1 3 a 1 2 d 4 5 b a 3 3 c c ...

Page 286: ...TRANSMISSION 5 77 ...

Page 287: ...OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 288: ...HE COOLANT on page 3 19 1 Coolant reservoir breather hose 1 2 Coolant 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 13 Radiator bracket 1 For installation reverse the removal proce dure...

Page 289: ... 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 a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Radi...

Page 290: ...RADIATOR 6 3 b Apply 100 kPa 14 50 psi 1 0 kg cm2 of pressure c Measure the indicated pressure with the gauge ...

Page 291: ...t Drain Refer to CHANGING 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 10 O ring 1 For installation reverse the removal proce dure ...

Page 292: ...Install O ring Oil cooler 1 Gasket 2 Oil cooler union bolt 3 NOTE Before installing 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 p...

Page 293: ...e Q ty Remarks Air 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 ...

Page 294: ... tem perature NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous 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 CHANG...

Page 295: ... or the coolant contains engine oil Right bottom cowling 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 ...

Page 296: ...er pump Order Job Parts to remove Q ty Remarks 1 Water pump cover 1 2 Gasket 1 3 Circlip 1 4 Impeller shaft along with the impeller 1 5 Water pump seal 1 6 Bearing 1 7 Oil seal 1 8 O ring 1 For installation reverse the removal proce dure ...

Page 297: ...ter pump housing 4 Remove Bearing 1 NOTE Remove the bearing from inside of the water pump housing 5 Remove Rubber damper holder 1 Rubber damper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Rubber damper 4 Rubber damper holder 5 Water pump seals O...

Page 298: ...E Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 Three Bond No 1215 2 to the water pump housing 3 3 Install Rubber damper holder 1 Rubber damper 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 New New Mechanical sea...

Page 299: ...mpeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lith ium 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 Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller Water pump bolt 12 Nm 1...

Page 300: ...WATER PUMP 6 13 ...

Page 301: ... INTAKE FUNNEL 7 6 INSTALLING THE INTAKE FUNNEL 7 7 CHECKING THE INTAKE FUNNEL OPERATION 7 7 INSTALLING THE AIR FILTER CASE 7 7 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL SIDE AND SECONDARY INJECTOR FUEL RAIL SIDE 7 7 THROTTLE BODIES 7 9 CHECKING THE PRIMARY INJECTORS 7 12 CHECKING THE THROTTLE BODIES 7 12 CHECKING THE ROLLOVER VALVE for California only 7 12 CHECKING THE FUEL PRESSURE 7 1...

Page 302: ... overflow hose 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel sender coupler 1 Disconnect 6 Fuel hose connector cover 1 7 Fuel hose fuel tank side 1 Disconnect 8 Fuel tank 1 9 Fuel tank upper cover 1 10 Fuel tank overflow hose fuel tank to hose joint 1 11 Fuel tank breather hose fuel tank to hose joint 1 Except for california 12 Fuel tank breather hose fuel tank to rollover valve 1 For calif...

Page 303: ...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 assembly 2 Check Diaphragms and gasket...

Page 304: ...urely 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 Fuel hose connector cover NOTE Attach the fuel hose connector cover 1 to the fuel hose connector 2 from the bottom Make sure that parts a are firmly attached t...

Page 305: ...ndary injector fuel rail side 1 Disconnect 5 Upper air filter case 1 6 Secondary injector holder 1 7 Cylinder 1 secondary injector coupler 1 Disconnect 8 Cylinder 2 secondary injector coupler 1 Disconnect 9 Cylinder 3 secondary injector coupler 1 Disconnect 10 Cylinder 4 secondary injector coupler 1 Disconnect 11 Sub wire harness 1 12 Secondary injector fuel rail 1 13 Secondary injector 4 14 Air f...

Page 306: ...on system hose air filter case to air cut off valve 1 Disconnect 19 Intake funnel servo motor 1 For installation reverse the removal proce dure Removing the air filter case and secondary injectors Order Job Parts to remove Q ty Remarks ...

Page 307: ...ose manually without using any tools Before removing the hose place a few rags in the area under where it will be removed EAS13S1001 REMOVING THE AIR FILTER CASE 1 Remove Upper air filter case NOTE Loosen the upper air filter case bolts in proper sequence as shown ET2C01017 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Damage Replace EAS13S1002 REMOVING THE INTAKE FUNNEL 1 Remove Intake funne...

Page 308: ...unnel operate smoothly strokes from the upper position to the lower seating position EAS13S1003 INSTALLING THE AIR FILTER CASE 1 Install Upper air filter case NOTE Tighten the upper air filter case bolts in proper sequence as shown ET2C01006 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL SIDE AND SECOND ARY INJECTOR FUEL RAIL SIDE 1 Connect Fuel hose primary injector fuel rail side and second...

Page 309: ...AIR FILTER CASE 7 8 To install the fuel hose onto the secondary injector fuel rail slide the fuel hose connector cover 1 on the end of the hose in the direc tion of the arrow shown 1 ...

Page 310: ... case Refer to AIR FILTER CASE on page 7 4 1 Canister purge hose throttle boby 4 to 3 way joint 1 2 Canister purge hose throttle boby 2 to 3 way joint 1 3 3 way joint 1 4 Canister purge hose 3 way joint to canister 1 5 Rollover valve 1 6 Fuel tank breather hose rollover valve to canis ter 1 7 Canister 1 8 Canister bracket 1 For installation reverse the removal proce dure ...

Page 311: ...ler 1 Disconnect 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 coupler 1 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Fuel hose 1 7 Throttle cable decelerator cable 1 8 Throttle cable accelerator cable 1 9 Throttle body assembly 1 10 Throttle body joint clamp 4 11 H...

Page 312: ... 1 Disconnect 4 Cylinder 3 primary injector coupler 1 Disconnect 5 Cylinder 4 primary injector coupler 1 Disconnect 6 Sub wire harness 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 For installation...

Page 313: ...lve 1 Damage faulty Replace NOTE Check that air flows smoothly only in the direction of the arrow shown in the illustra tion The rollover valve must be in an upright posi tion when checking the airflow EAS27010 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat Refer to GENERAL CHASSIS on page 4 1 b Disconnect the fuel hose 1 from the fuel tank WARNING EW2C01008 Cover fuel ho...

Page 314: ...ecified range g After adjusting the throttle position sensor angle tighten the throttle position sensor screws 4 ET2C01008 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PUL LEY 1 Check Throttle position sensor for throttle cable pulley Refer to CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY on page 8 98 2 Adjust Throttle position sensor angle a Connect the throttle pos...

Page 315: ...ensor screws 4 ET2C01009 INSTALLING THE THROTTLE BODY JOINTS 1 Install Throttle body joints 1 NOTE Be sure to install the throttle body joints with the L mark onto the throttle body openings for cylinders 1 and 2 and the joints with the R mark onto the openings for cylinders 3 and 4 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Output voltage 0 630 0 730 V Throttl...

Page 316: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM 2 1 2 4 3 4 3 6 4 5 A A ...

Page 317: ...M 7 16 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 Refer to AIR FILTER CASE on page 7 4 1 Air induction system cover 1 2 Air induction system solenoid coupler 1 Disconnect 3 Air induction system hose air filter case to air cut off valve 1 4 Air induction system hose air cut off valve to cylinder head cover 2 5 Air cut off valve 1 For installation reverse the removal proce dure ...

Page 319: ...IR INDUCTION SYSTEM 7 18 Removing the reed valves 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 ...

Page 320: ... to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture 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 tem perature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Chec...

Page 321: ...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 49 FUEL PUMP SYSTEM 8 73 CIRCUIT DIAGRAM 8 73 TROUBLESHOOTING 8 75 ELECTRICAL COMPONENTS 8 77 CHECKING THE SWITCHES 8 8...

Page 322: ... 96 CHECKING THE SPEED SENSOR 8 96 CHECKING THE RADIATOR FAN MOTORS 8 97 CHECKING THE COOLANT TEMPERATURE SENSOR 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 8 98 CHECKING THE FUEL PUMP 8 98 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 99 CHECKING THE ATMOSPHERIC PRESSURE SENSOR 8 99 CHECKING THE CYLINDER IDENTI...

Page 323: ......

Page 324: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 325: ...nit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 22 ECU engine control unit 23 Spark plug 24 Cylinder 1 ignition coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 40 Crankshaft position sensor 47 Lean angle sensor 64 Engine stop switch ...

Page 326: ...hen both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from 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 side stand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestan...

Page 327: ...YSTEM 8 4 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Neutral switch 12 Engine ground ...

Page 328: ... THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 92 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 92 Replace the ignition coil s...

Page 329: ...n page 8 81 Replace the sidestand switch 11 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 89 Replace the relay unit 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 91 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 93 Replace the lean angle sensor 14 Check the entire ...

Page 330: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 331: ... switch 4 Ignition fuse 6 Main fuse 7 Battery 8 Starter relay 10 Starter motor 11 Engine ground 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 64 Engine stop switch 65 Start switch 70 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 con ditions 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: ...nals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 93 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 34 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to...

Page 335: ...SWITCHES on page 8 81 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 14 Check the entire starting system s wiring R...

Page 336: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

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 86 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 94 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 94 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT ...

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

Page 340: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 341: ... Engine ground 22 ECU engine control unit 57 High beam indicator light 60 Meter light 68 Dimmer switch 77 Headlight low beam 78 Headlight high beam 79 License plate light 81 Tail brake light 82 Headlight relay on off 83 Headlight relay dimmer 85 Headlight fuse ...

Page 342: ... 84 Replace the bulb s and bulb socket s 2 Check the fuses Main and headlight Refer to CHECKING THE FUSES on page 8 85 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 5 Check the dimmer switch Refer to...

Page 343: ...ight relay dimmer Refer to CHECKING THE RELAYS on page 8 89 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 system s wiring This circuit is OK ...

Page 344: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 345: ...meter 53 Shift timing indicator light 54 Multi function meter 56 Coolant temperature warning light 58 Left turn signal indicator light 59 Right turn signal indicator light 61 Oil level switch 63 Front brake light switch 66 Turn signal relay 69 Horn switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn signal position light 76 Front ...

Page 346: ...r to CHECKING THE FUSES on page 8 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the si...

Page 347: ...81 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 81 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 signal ing system s wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB...

Page 348: ... 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 91 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 s...

Page 349: ... on page 8 96 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 97 Replace the coolant temperature sen sor 2 Check the entire signaling system s wiring Refer to...

Page 350: ...e signal ing system s wiring Replace the meter assembly 1 Check that the shift timing indicator light is set to come on and that the brightness level of the light is adjusted properly Refer to FEATURES on page 1 2 Replace the meter assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK...

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

Page 352: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 353: ...use 6 Main fuse 7 Battery 11 Engine ground 22 ECU engine control unit 42 Coolant temperature sensor 86 Radiator fan motor relay 87 Right radiator fan motor fuse 88 Left radiator fan motor fuse 89 Right radiator fan motor 90 Left radiator fan motor ...

Page 354: ... battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 97 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 89 Replace the radiator fan motor relay 6 Check the coolant temperature Refer to CHECKING THE COOL ANT...

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

Page 356: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 357: ...coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 28 Primary injector 1 29 Primary injector 2 30 Primary injector 3 31 Primary injector 4 32 Secondary injector 1 33 Secondary injector 2 34 Secondary injector 3 35 Secondary injector 4 36 Air induction system solenoid 37 Throttle servo motor 38 EXUP servo motor 39 O2 sensor 40 Crankshaft position sensor 41 Air ...

Page 358: ...remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and it c...

Page 359: ... circuit Intake air pressure sensor open or short circuit detected Able Able 14 Intake air pressure sensor hose line piping system Intake air pressure sensor hose system malfunction clogged or detached hose Able Able 15 Throttle position sen sor for throttle valves open or short circuit loose connection Throttle position sensor for throttle valves open or short circuit detected Throttle position s...

Page 360: ...on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 36 Cylinder 4 ignition coil open circuit Primary lead of the cylinder 4 ignition coil open circuit detected Able depending on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 39 Primary injector open circuit Primary injector open circuit detected Able depending on the num ber of fa...

Page 361: ...ottle position sensor for throttle cable pulley coupler connection is loose Able Unable Able Unable 60 Throttle servo motor Throttle servo motor open or short circuit detected Motor is defective or ECU internal malfunction Able Unable Able Unable Fault code No Item Symptom Able unable to start Able unable to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ...

Page 362: ...g the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunct...

Page 363: ...r d01 appears on the clock LCD 6 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT 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...

Page 364: ...ttle valves open or short circuit detected Throttle position sensor for throttle valves coupler con nection 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 detected or loose connec tion Open or short circ...

Page 365: ... circuit detected in the primary lead of the cylinder 1 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 30 34 Open circuit detected in the primary lead of the cylinder 2 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 31 35 Open circuit detected in the primary lead of the cylinder 3 ignition coil Open circuit in ...

Page 366: ...ottle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley cou pler connection is loose Open or short circuit in wire harness Defective throttle position sensor Improperly installed throttle position sensor Malfunction in ECU 14 15 60 Throttle servo motor open or short circuit detected Defective throttle servo motor Malfunction...

Page 367: ... meter display value without cranking the engine 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured air temperature with the meter display value 06 Coolant temperature Displays the coolant tempera ture Compare the actually mea sured coolant temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number increases when the rear ...

Page 368: ...ck with throttle grip fully opened 20 Sidestand switch Set ON OFF the sidestand switch with the transmis 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 detect...

Page 369: ...de numbers are shown the display repeats To reinstate set the engine stop switch from to 70 Control number 00 Diag nostic code No Item Actuation Checking method 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one sec ond intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 31 Cylinder 2 ignition coil Actuate...

Page 370: ...tes the primary injector 3 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 3 five times 39 Primary injector 4 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 Actuate...

Page 371: ...ning 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 motor relay Actuates the radiator fan motor relay five times at one second intervals ON 2 sec onds OFF 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the radiator fan mot...

Page 372: ...he cylinder identifi cation sensor when the engine is started or while the vehicle is being driven Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of cylinder identifi cation sensor Check for looseness or pinching Cranking the engine 2 Connections Cylinder identification sensor coupler Main wire harness ECU coupler Che...

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 securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft posi tion sensor coupler and ECU coupler 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 INTAKE AIR PRESSURE SEN SOR on page 8 100 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached...

Page 375: ...ing 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 securely 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: ...cuit 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 81 Fault code No 20 Symptom When the main switch is turned to ON the atmospheric pressure senso...

Page 378: ...sor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 97 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: ...ric pressure sen sor Execute the diagnostic mode Code No 02 Replace if defective Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 99 Fault code No 24 Symptom No normal signal is received from the O2 sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed state of O2 sensor Check for looseness or pinching Execute the di...

Page 380: ...imary lead of the cylinder 1 ignition coil Diagnostic code No 30 Cylinder 1 ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfun...

Page 381: ...e pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 2 igni tion 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 2 ignition coil coupler and ECU coupler red black red black gray red ...

Page 382: ...lled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 3 igni tion 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 black orange green ...

Page 383: ...t Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 4 igni tion 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 coupler main wire harness red black red black gr...

Page 384: ...ay be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 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: ...lled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Execute the diagnostic 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: ... pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Reinstated automatically 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 light green light green ...

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 securely A 3 Open or short circuit in lead Repair or replace if there is an open or short circuit Between speed sensor cou pler 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 securely 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 a...

Page 389: ...If there is a malfunction repair it and connect the coupler securely 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: ...N Readjust the exhaust gas vol ume 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 engine and operating it at idle 2 Open or short circuit in wire harness Re...

Page 391: ...d in the specified posi tion 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 securely 3 Open or short circuit in wire harness Repair or replace if there is ...

Page 392: ...it 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 assembly 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: ...er 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 securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue 3 Malfunction i...

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

Page 396: ...FUEL PUMP SYSTEM 8 73 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

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 13 Relay unit 15 Fuel pump relay 18 Fuel pump 22 ECU engine control unit 64 Engine stop switch ...

Page 398: ...6 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 8 89 Replace the relay unit 6 Check the fuel pump Refer to C...

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

Page 400: ...ELECTRICAL COMPONENTS 8 77 EAS27970 ELECTRICAL COMPONENTS ...

Page 401: ...Main fuse 7 Fuel injection system fuse 8 Starter relay 9 Neutral switch 10 EXUP servo motor 11 Rear brake light switch 12 O2 sensor 13 Sidestand switch 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Fuse box radiator fan motor signaling sys tem ignition headlight ...

Page 402: ...ELECTRICAL COMPONENTS 8 79 1 5 4 3 2 6 7 8 9 10 12 13 11 14 15 16 17 18 ...

Page 403: ...control unit 7 Lean angle sensor 8 Relay unit 9 Turn signal hazard relay 10 Crankshaft position sensor 11 Intake air pressure sensor 12 Throttle servo motor 13 Throttle position sensor for throttle cable pulley 14 Throttle position sensor for throttle valves 15 Cylinder identification sensor 16 Radiator fan motor relay 17 Headlight relay dimmer 18 Headlight relay on off ...

Page 404: ...ELECTRICAL COMPONENTS 8 81 EAS27980 CHECKING THE SWITCHES ...

Page 405: ...NENTS 8 82 1 Clutch switch 2 Main switch 3 Dimmer switch 4 Horn switch 5 Turn signal switch 6 Sidestand switch 7 Front brake light switch 8 Engine stop switch 9 Start switch 10 Neutral switch 11 Rear brake light switch ...

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

Page 407: ...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 removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touchin...

Page 408: ...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 electrical circuit WARNING EWA13310 Neve...

Page 409: ...ls will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter ies The MF battery should be charged according to the instructions for the charging method If the battery is over charged the electrolyte level will drop considerably Therefore take special care when charging the ...

Page 410: ...arger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery 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 disconnect the battery charger and let the battery cool before reconnecting it H...

Page 411: ...rcuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the...

Page 412: ...s shown Check the relay operation Out of specification Replace Starter relay 1 Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C R B R R R W R 2 1 4 3 W L 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity betwee...

Page 413: ...relay input voltage 2 Check Turn signal hazard relay output voltage Out of specification Replace 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 terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal...

Page 414: ...ter 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...

Page 415: ...k Secondary coil resistance Out of specification Replace a Connect the pocket tester Ω 1k to the ignition 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 Primary coil resistance 0 85 1 15 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red black 1 Negative teste...

Page 416: ...t voltage Out of specification Replace a Connect the lean angle sensor coupler to the lean angle sensor b 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 ET2C01012 CHECKING THE STARTER MOTOR OPERA TION 1 Check Starter motor operation Does not operate Perform t...

Page 417: ...ster Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the recti fier regulator a Set the engine tachometer to the cylinder 1 ignition coil b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown Stator coil resistance 0 12 0 18 Ω at 20 C 68 F Pocket te...

Page 418: ...28190 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Out of specification Replace the oil level switch a Connect the pocket tester Ω 100 to the oil level switch terminal as shown Coil resistance 1 15 1 25 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe horn terminal 1 Neg...

Page 419: ...ess side as shown b Turn the main switch to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V Maximum level position B Positive tester probe connector white 1 Negative tester probe body earth 2 Fuel sender resistance 900 1050 Ω at 25 C...

Page 420: ...n Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 NOTE Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Slowly heat the coolant then let it cool down to the specified temperature e Measure the coolant temperature sensor resi...

Page 421: ...ket tester Ω 1k to the throttle position sensor for throttle cable pulley terminal as shown b Measure the throttle position sensor for throttle cable pulley maximum resistance 3 Install Throttle position sensor for throttle cable pulley NOTE When installing the throttle position sensor for throttle cable pulley adjust its angle properly Refer to ADJUSTING THE THROTTLE POSI TION SENSOR FOR THROTTLE...

Page 422: ...e fuel pump operation EAS28370 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system sole noid coupler from the air induction system solenoid b Connect the pocket tester Ω 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance EAS28380 CH...

Page 423: ...ut voltage rises to approximately 4 8 V once EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the intake air pressure sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink 1 Negative tester probe black blue 2 Cylinder identific...

Page 424: ...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 ter minals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature ...

Page 425: ...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 426: ...l 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 coi...

Page 427: ...ized 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 Clutch ...

Page 428: ...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 Cracked or damaged cap bolt O ring Malfunction Bent...

Page 429: ...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 connection Damaged or f...

Page 430: ...gnal indicator light 59 Right turn signal indicator light 60 Meter light 61 Oil level switch 62 Right handlebar switch 63 Front brake light switch 64 Engine stop switch 65 Start switch 66 Turn signal relay 67 Left handlebar switch 68 Dimmer switch 69 Horn switch 70 Clutch switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn signal ...

Page 431: ......

Page 432: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 433: ... G R L B Gy G B L B B L W R B O G R B Gy G O B R L R L G W L W L W L W L W L R L R L G Sb W Sb W Sb W Sb W Sb W R L R L G Br Y Br Y Br Y Br Y Br Y R L R L G Br B Br B Br B Br B Br B R L L B R L G B R L R B R L Br R R W B B B G P L L L W B R W L W R W B W L W R B Y B R W Y Lg R W O O B R L Y L L B B G Y B Y G O G G B R B Gy G Gy R Gy G Lg R Br R Sb W Sb W L Y L B Y R Y B L W R W P W W L Sb W R B G ...

Page 434: ...HARNESS WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 3 HEADLIGHT SUB WIRE HARNESS 2 HEADLIGHT SUB WIRE HARNESS 1 WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS YZFR6X C WIRING DIAGRAM ...

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