Yamaha 2009 XP500Y TMAX Service Manual Download | Manualshive

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TROUBLESHOOTING

9-3

• Thermostat
• Thermostat stays closed
• Oil cooler
• Clogged or damaged oil cooler
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe

Fuel system

1. Throttle body

• Faulty throttle body
• Damaged or loose throttle body joint

2. Air filter

• Clogged air filter element

Chassis

1. Brake(s)

• Dragging brake

Electrical system

1. Spark plug(s)

• Incorrect spark plug gap
• Incorrect spark plug heat range

2. Ignition system

• Faulty ECU (engine control unit)

EAS28610

OVERCOOLING

Cooling system

1. Thermostat

• Thermostat stays open

EAS28620

POOR BRAKING PERFORMANCE

• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level

EAS28660

FAULTY FRONT FORK LEGS

Leaking 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 bolt
• Damaged damper rod bolt copper washer
• Cracked or damaged cap bolt O-ring

Malfunction

• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level

EAS28670

UNSTABLE HANDLING

1. Handlebar

• Bent or improperly installed handlebar

2. Steering head components

• Improperly installed upper bracket
• Improperly installed lower bracket

(improperly tightened ring nut)

• Bent steering stem
• Damaged ball bearing or bearing race

3. Front fork leg(s)

• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front

fork legs)

• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube

4. Swingarm

• Worn bearing or bushing
• Bent or damaged swingarm

5. Rear shock absorber assembly

• Faulty rear shock absorber spring
• Leaking oil or gas

6. Tire(s)

• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear

7. Wheel(s)

• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout

8. Frame

• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race

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Summary of Contents for 2009 XP500Y TMAX

Page 1: ...2009 SERVICE MANUAL XP500Y LIT 11616 22 08 4B5 28197 10 ...

Page 2: ... Yamaha Motor Corporation U S A First edition March 2008 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 22 08 ...

Page 3: ...th 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 sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

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

Page 5: ... 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a n...

Page 6: ......

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

Page 8: ......

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

Page 10: ...EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the storage box This information will be needed to order spare parts 1 1 ...

Page 11: ...o deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of a conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a ...

Page 12: ...the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU engine control unit Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temperature sensor and O2 sensor enable the ECU engine control unit to determine the injection duration The injection tim...

Page 13: ...nce the last V belt re placement TIP Be sure to turn the key to ON before using the SELECT and RESET buttons When the key is turned to ON all of the dis play segments of the multi function display will appear one after the other and then disappear in order to test the electrical circuits Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range...

Page 14: ...e tripmeter manually it will reset itself automatical ly and the display will return to the prior mode af ter refueling and traveling 5 km 3 mi TIP The display cannot be changed back to F Trip after pushing the RESET button Oil change indicator OIL This indicator flashes at the initial 1000 km 600 mi then at 5000 km 3125 mi and every 5000 km 3125 mi thereafter to indicate that the en gine oil shou...

Page 15: ...he RESET button for at least 3 seconds If the V belt is changed before the V belt re placement indicator V BELT flashes i e be fore the periodic V belt change interval has been reached the indicator V BELT must be reset after the V belt change for the next periodic V belt change to be indicated at the correct time The electrical circuit of the indicator can be checked according to the following pr...

Page 16: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

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

Page 18: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP 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 m...

Page 19: ...r to the list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 9 5 33 7 8 8 63 8 64 8 65 8 69 8 70 8 71 8 72 8 73 8 74 8 75 8 76 8 77 8 78 Valve lapper 90890 04101 Valve lapping tool YM A8...

Page 20: ...ssure gauge set 90890 03120 3 13 Oil pressure adapter B 90890 03124 3 13 Pressure gauge 90890 03153 YU 03153 3 13 7 4 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 26 4 60 Damper rod holder 90890 01460 4 53 4 54 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 53 4 54 Tool name Tool No Illustration Reference pages 66 8 ...

Page 21: ...aha bond No 1215 90890 85505 Three Bond No 1215 5 14 5 44 5 52 5 69 6 12 Valve spring compressor 90890 04019 YM 04019 5 19 5 24 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 19 5 24 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 21 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 22: ...112 5 21 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 21 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 27 Sheave holder 90890 01481 5 41 5 44 5 45 Locknut wrench 90890 01348 YM 01348 5 41 5 44 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 23: ...cket YM 04135 5 41 5 44 Oil seal guide ø41 90890 01396 5 43 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 50 5 51 5 52 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 50 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 57 5 61 Tool name Tool No Illustration Reference pages ...

Page 24: ...04086 YM 91042 5 57 5 60 Plane bearing installer 90890 04139 5 73 5 76 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Tool name Tool No Illustration Reference pages YU 24460 01 YU 33984 ...

Page 25: ...seal installer YM 33221 A 6 12 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 12 Fuel pressure adapter 90890 03181 7 4 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 72 Tool name Tool No Illustration Reference pages ...

Page 26: ...SPECIAL TOOLS 1 17 ...

Page 27: ...TIONS 2 13 TIGHTENING TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 26 LUBRICATION SYSTEM DIAGRAMS 2 27 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING 2 35 ...

Page 28: ...ions Overall length 2195 mm 86 4 in Overall width 775 mm 30 5 in Overall height 1445 mm 56 9 in Seat height 800 mm 31 5 in Wheelbase 1580 mm 62 2 in Ground clearance 125 mm 4 92 in Minimum turning radius 2800 mm 110 2 in Weight With oil and fuel 222 0 kg 489 lb Maximum load 193 kg 425 lb ...

Page 29: ...PI service SG type or higher JASO standard MA Engine oil quantity Total amount 3 60 L 3 81 US qt 3 17 Imp qt Without oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt With oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Oil pressure hot 150 0 kPa 1200 r min 21 8 psi 1200 r min 1 50 kgf cm 1200 r min Chain drive oil Type SAE 80 API GL 4 Hypoid gear oil Quantity 0 70 L 0 ...

Page 30: ...er pump type Single suction centrifugal pump Reduction ratio 23 19 1 210 Impeller shaft tilt limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK CR7E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 14 97 15 57 cm 0 91 0 95 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft cap inside diameter 23 000 23 021 mm 0 9055 0 9063 in Camshaft journa...

Page 31: ...0118 in Valve dimensions Valve head diameter A intake 24 90 25 10 mm 0 9803 0 9882 in Valve head diameter A exhaust 21 90 22 10 mm 0 8622 0 8701 in Valve face width B intake 1 140 1 980 mm 0 0449 0 0780 in Valve face width B exhaust 1 140 1 980 mm 0 0449 0 0780 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in L...

Page 32: ...er head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve spring Free length intake 35 59 mm 1 40 in Limit 33 81 mm 1 33 in Free length exhaust 35 59 mm 1 40 in Limit 33 81 mm 1 33 in Installed length intake 30 39 mm 1 20 in Installed length exhaust 30 39 mm 1 20 in Spring rate ...

Page 33: ...008 0 0018 in Limit 0 15 mm 0 0059 in Diameter D 65 965 65 980 mm 2 5970 2 5976 in Height H 9 0 mm 0 35 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043 mm 0 5922 in Piston pin outside diameter 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 00...

Page 34: ...m 0 5907 0 5913 in Crankshaft Width A 50 00 50 60 mm 1 969 1 992 in Width B 118 55 118 60 mm 4 67 4 67 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Big end radial clearance E 0 026 0 050 mm 0 0010 0 0020 in Journal oil clearance using plastigauge 0 040 0 082 mm 0 0016 0 0032 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft journal dia...

Page 35: ...Primary reduction system Spur gear helical gear Primary reduction ratio 52 32 36 22 2 659 Secondary reduction system Chain drive Secondary reduction ratio 41 25 40 29 2 262 Operation Centrifugal automatic type Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 4B...

Page 36: ... 69 kΩ at 20 C 68 F Coolant temperature sensor resistance 2 32 2 59 kΩ at 20 C 68 F 310 326 Ω at 80 C 176 F Idling condition Engine idling speed 1100 1300 r min Intake vacuum 33 0 kPa 9 7 inHg 248 mmHg Water temperature 85 0 100 0 C 185 00 212 00 F Oil temperature 70 0 C 158 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 37: ...mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70R15 M C 56H Manufacturer model DUNLOP GPR 100F Manufacturer model BRIDGESTONE BT011F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 160 60R15 M C 67H Manufacturer model DUNLOP GPR 100L Manufacturer model BRIDGESTONE BT012R Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loa...

Page 38: ...0 8 mm 0 03 in Master cylinder inside diameter 14 0 mm 0 55 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 38 5 Center to lock angle right 38 5 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fork spring free length 303 9 ...

Page 39: ...e K2 294 00 N mm 1678 74 lb in 29 98 kgf mm Spring stroke K1 0 0 28 8 mm 0 00 1 13 in Spring stroke K2 28 8 43 0 mm 1 13 1 69 in Optional spring available No Enclosed gas air pressure STD 4900 kPa 696 9 psi 49 0 kgf cm Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in ...

Page 40: ...F004T39871 MITSUBISHI Standard output 14 0 V 27 0 A 5000 r min Standard output 14 0 V 378 W 5000 r min Stator coil resistance 0 225 0 275 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH678 11 SHINDENGEN Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 22 0 A Withstand voltage 200 0 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Manufa...

Page 41: ... relay Model manufacturer RC19 075A MITSUBA Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 06 1 11 Ω at 20 C 68 F Performance 105 118 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Built in self canceling device No Turn signal blinking frequency 75 95 cycles...

Page 42: ...JJ MATSUSHITA Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A Fuel injection system fuse 10 0 A Backup fuse 10 0 A Spare fuse 30 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A ...

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

Page 44: ...tor rotor nut 1st M18 1 65 Nm 6 5 m kg 47 ft lb See TIP Generator rotor nut final M18 1 Specified angle 120 See TIP Timing chain tensioner bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Timing chain guide intake side bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Water pump housing cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Water pump assembly bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Water pump inlet and outlet pipes bolt M6 2 1...

Page 45: ...lb Generator cover bolt M6 19 10 Nm 1 0 m kg 7 2 ft lb Outer V belt case bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Outer V belt case bolt M8 6 24 Nm 2 4 m kg 17 ft lb Inner V belt case plate bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Inner V belt case bolt M8 2 24 Nm 2 4 m kg 17 ft lb Crankshaft end access cover screw M6 3 7 Nm 0 7 m kg 5 1 ft lb V belt case air filter case screw M6 3 7 Nm 0 7 m kg 5 1 ft lb Gen...

Page 46: ...ghten them further to reach the specified angle 120 Secondary sheave nut M18 1 90 Nm 9 0 m kg 65 ft lb BEL RAY assem bly lube Crankshaft right end bearing re tainer screw M6 1 11 Nm 1 1 m kg 8 0 ft lb Secondary shaft bearing retainer bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Stator coil bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor bolt M5 2 7 Nm 0 7 m kg 5 1 ft lb Starter motor bolt M6 2...

Page 47: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence ...

Page 48: ...bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Frame cross member bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Muffler bracket nut M10 1 32 Nm 3 2 m kg 23 ft lb Tail bracket bolt M8 2 16 Nm 1 6 m kg 11 ft lb Taillight assembly bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Seat hinge assembly bolt M8 4 16 Nm 1 6 m kg 11 ft lb Seat hinge damper ball joint M8 2 16 Nm 1 6 m kg 11 ft lb Fuel tank bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Fuel...

Page 49: ...2 40 Nm 4 0 m kg 29 ft lb Brake hose union bolt M10 4 30 Nm 3 0 m kg 22 ft lb Brake master cylinder holder bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Brake lever pivot nut M6 2 6 Nm 0 6 m kg 4 3 ft lb Grip end M16 2 26 Nm 2 6 m kg 19 ft lb Front fender bolt M6 6 7 Nm 0 7 m kg 5 1 ft lb Front wheel axle M18 1 72 Nm 7 2 m kg 52 ft lb Front wheel axle pinch bolt M8 1 20 Nm 2 0 m kg 14 ft lb Rear wheel axle n...

Page 50: ...7 Nm 0 7 m kg 5 1 ft lb Rear brake lock cable holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Centerstand bracket nut M10 4 55 Nm 5 5 m kg 40 ft lb Centerstand nut M10 2 55 Nm 5 5 m kg 40 ft lb Sidestand nut M10 1 39 Nm 3 9 m kg 28 ft lb Passenger footrest bolt M8 4 30 Nm 3 0 m kg 22 ft lb ECU engine control unit bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Tran...

Page 51: ...t threads and nut seats Balancer connecting rod bolt threads and nut seats Crankshaft journal bearings and crankshaft journals Balancer piston surface Balancer cylinder inner surface Balancer piston pin Camshaft cam lobes and camshaft journals Valves and valve stems Valve stem seals Valve pads Valve lifters Impeller shaft Oil pump rotors inner and outer Oil pump driven gear shaft Oil filter cartri...

Page 52: ...lube Secondary sheave nut seats BEL RAY assembly lube Outer V belt case crankshaft right end point Pivot shaft taper roller bearing Cylinder head cover inner gaskets mating surface Yamaha bond No 1215 Three bond No 1215 Timing chain guide upper side mating surface Yamaha bond No 1215 Three bond No 1215 Crankcase mating surfaces Yamaha bond No 1215 Three bond No 1215 Inner V belt case seal mating s...

Page 53: ...n drive oil Transmission chain drive secondary driven gear oil seal lip Rear wheel and rear wheel drive hub mating surface Rear wheel drive hub spline Rear shock absorber assembly bearing inner surface Rear shock absorber assembly spacer and collar Pivot shaft oil seal and collar Rear shock absorber assembly front bolt seats Seat lock metal to metal moving parts Seat hinge metal to metal moving pa...

Page 54: ...LUBRICATION SYSTEM DIAGRAMS 2 27 EAS4B51021 LUBRICATION SYSTEM DIAGRAMS EAS20410 LUBRICATION DIAGRAMS D C D C C C D A A A A B B B A A C C D D B B 1 2 5 6 5 5 2 4 3 ...

Page 55: ...LUBRICATION SYSTEM DIAGRAMS 2 28 1 Oil delivery pipe 2 Oil pump 3 Oil cooler 4 Oil filter cartridge 5 Oil pipe 6 Oil strainer ...

Page 56: ...LUBRICATION SYSTEM DIAGRAMS 2 29 1 2 3 4 4 ...

Page 57: ...LUBRICATION SYSTEM DIAGRAMS 2 30 1 Secondary shaft 2 Drive axle 3 Clutch 4 Crankshaft ...

Page 58: ...COOLING SYSTEM DIAGRAMS 2 31 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 15 16 17 18 9 10 11 12 6 17 8 10 12 19 11 13 14 16 15 20 13 14 ...

Page 59: ...mostat outlet hose 7 Oil cooler outlet hose 8 Thermostat 9 Oil cooler 10 Coolant hose 11 Water pump inlet pipe 12 Water pump outlet pipe 13 Oil cooler inlet hose 14 Radiator outlet hose 15 Fast idle plunger outlet coolant hose 16 Radiator 17 Cooling system air bleed hose 18 Coolant reservoir hose 19 Water pump 20 Fast idle plunger ...

Page 60: ...COOLING SYSTEM DIAGRAMS 2 33 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 61: ...ose 2 Cooling system air bleed hose 3 Radiator cap 4 Radiator filler pipe 5 Radiator filler hose 6 Coolant reservoir hose 7 Radiator 8 Radiator inlet hose 9 Coolant reservoir 10 Coolant reservoir breather hose 11 Oil cooler outlet hose 12 Coolant pipe ...

Page 62: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING A B C D E F G H I J K L M N O P 1 1 2 1 2 2 3 4 4 4 5 6 5 6 7 7 5 6 7 8 B C A A B C ...

Page 63: ...f the vehicle H Route the throttle cables behind the rear brake hose I Route the left handlebar switch lead behind the handlebar and then route it through the opening in the handlebar toward the front of the vehicle J Route the rear brake hose in front of the handlebar and then route it through the opening in the handlebar toward the rear of the vehicle K Route the left handlebar switch lead behin...

Page 64: ...CABLE ROUTING 2 37 A B A C D E F G H I J K L 1 2 1 2 3 3 4 5 6 6 7 A A A A A A A A ...

Page 65: ... mm 0 8 1 2 in E Fasten the speed sensor lead and front brake hose to left front brake caliper with a plastic locking tie making sure to align the tie with the white paint mark on the lead F Make sure that the horn coupler is completely seated on the horn terminals G Pass the speed sensor lead between the front brake pipe and the wire harness to horn H Point the end of the plastic locking tie inwa...

Page 66: ... J L M N O O P P Q Q N M L K K AB AA AA A B C D E F G H I J J K L M N O N N N O P Q R U V W W X X X Y Z 1 1 1 2 2 1 2 2 1 2 3 4 5 6 7 8 9 10 10 10 10 13 11 11 11 11 11 11 11 12 12 12 12 12 13 11 12 13 14 14 15 15 15 15 15 15 15 15 15 14 14 15 15 16 16 16 16 16 17 18 19 20 21 32 22 23 24 25 27 27 27 26 27 28 29 30 30 31 34 33 33 S T ...

Page 67: ... engine mounting bolt F Route the fuel tank overflow hose and sidestand switch lead to the inside of the radiator outlet hose G Route the sidestand switch lead to the front of the footrest board bracket H Install the ignition coil connectors so that the leads are routed outward I Route the wire harness to left headlight to the outside of the starter motor lead J To left headlight unit K Cut off th...

Page 68: ... J J K K L L M M F F G G H H C C I I B D A A B AA AB A B C D E F G H I J K L M N O O P P Q R S T U V R W X Y Z 3 3 3 3 3 1 2 3 4 5 5 5 5 5 5 4 5 6 7 7 8 9 9 10 10 11 11 12 13 13 14 14 14 15 16 16 16 17 18 19 18 19 20 21 22 23 34 24 25 26 27 27 27 28 29 29 30 29 31 32 33 ...

Page 69: ...e sensor under the fuel tank bracket J Route the wire harnesses to fuel pump intake air pressure sensor and throttle position sensor to the front of the fuel tank bracket K Connect the main switch coupler and fuel injector couplers and then install the rubber cover around the couplers making sure to face the opening of the cover upward L Fasten the main switch lead with the holder making sure that...

Page 70: ... L L K K J J D D C C B B A A G G F F E E I H A B C D E F G H I J K L M N O P Q R S T 1 2 3 6 6 3 4 5 6 7 8 9 10 10 10 11 12 13 14 14 15 15 16 15 16 16 16 16 17 17 18 18 19 20 21 22 22 23 23 23 J C C D E F F E D G G B L L K K B J ...

Page 71: ...re to position the white protector on the cable to the front of the holder G Route the rear brake lock cable to the inside of the outer V belt case bolt H Position the plastic locking tie to the front of the holder on the rear cowling assembly making sure that the tie contacts the holder I Fasten the seat lock cable with the portion of the holder that has the smaller diameter J Face the catch of t...

Page 72: ...CABLE ROUTING 2 45 A A A B B C C E E D D E A B C C B E A B C D E F G H I 1 1 1 1 3 3 3 3 3 2 2 4 ...

Page 73: ...assenger footrest making sure to fit the projection on the holder into the hole in the footrest E Point the open ends of the holder inward F Install the rear brake hose onto the rear brake caliper making sure that the pipe section on the end of the hose contacts the rib on the caliper G Route the rear brake lock cable under the frame cross member and fuel tank bracket H Route the rear brake lock c...

Page 74: ...CABLE ROUTING 2 47 A A B A B A B C D E F G B G G H I J J K L M O 1 2 1 2 3 3 4 4 5 5 6 7 8 9 10 Q P N ...

Page 75: ...d G Install the hose up to the bend in the hose fitting H Install the hose onto the hose fitting of the cylinder head making sure that the hose contacts the head I Position the hose clamp 1 4 mm 0 04 0 16 in from the end of the hose making sure to point the ends of the clamp downward J Face the white paint mark on the hose to the left K Face the yellow paint mark on the hose forward L Position the...

Page 76: ...CABLE ROUTING 2 49 B B A B C D E F G H I J K K K K L M N N O P Q R S T U 1 2 3 1 2 3 3 3 3 3 4 4 4 5 5 5 5 4 5 6 6 6 3 7 7 7 7 7 8 8 9 8 9 10 A D C B B A C E D E ...

Page 77: ...he holder on the frame cross member making sure to align the yellow paint mark on the hose with the holder H Attach the holders to the frame cross member at the locations shown in the illustration I Face the white paint mark on each hose upward Position each hose clamp 1 4 mm 0 04 0 16 in from the end of the respective pipe making sure to point the ends of the clamp upward J Fasten the canister pu...

Page 78: ...CABLE ROUTING 2 51 ...

Page 79: ...ECKING THE CYLINDER HEAD BREATHER HOSE 3 16 CHECKING THE EXHAUST SYSTEM 3 16 CHECKING THE CANISTER 3 17 CHECKING THE COOLANT LEVEL 3 17 CHECKING THE COOLING SYSTEM 3 17 CHANGING THE COOLANT 3 18 CHASSIS 3 21 ADJUSTING THE FRONT DISC BRAKE 3 21 ADJUSTING THE REAR DISC BRAKE 3 21 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 22 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRO...

Page 80: ...ELECTRICAL SYSTEM 3 30 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 REPLACING THE HEADLIGHT BULBS 3 30 ADJUSTING THE HEADLIGHT BEAMS 3 30 ...

Page 81: ......

Page 82: ...eck fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 12000 mi 19000 km or 18 months 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 Check and adjust engine idle speed a...

Page 83: ...ck operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Engine oil Change When the oil change indicator flashes Check oil level and vehicle for oil leakage 19 Engine oil filter cartridge Replace At 12500 mi 20000 km and thereafter every 12500 mi 20000 km 20 Cooling system Check coolant level and vehi cle for coola...

Page 84: ... brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every 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 ...

Page 85: ...ead cover gasket Refer to CAMSHAFTS on page 5 6 5 Remove Timing mark accessing plug 1 Crankshaft end access cover 2 6 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 I mark a on the gen erator rotor with the mark b on the generator cover TIP TDC on the compression stroke can be found when the cylinde...

Page 86: ... fasten the timing chain with a wire to re trieve it if it falls into the crankcase 8 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 TIP 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 in stalled in the correct place...

Page 87: ...umber according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 158 Rounded value 160 New valve pad number 160 f Install the new valve pad 1 and the valve lift er 2 TIP Lubricate the valve pad with molybdenum dis ulfide grease Lubricate the valve lifter with engine oil The valve lifter must turn s...

Page 88: ... centerstand 2 Remove Bottom cowling Refer to GENERAL CHASSIS on page 4 1 3 Remove Synchronizing pipe caps 1 4 Install Vacuum gauge 1 onto the synchronizing pipes Digital tachometer onto the spark plug lead of cylinder 1 5 Start the engine and let it warm up for several minutes 6 Check Engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 8 7 Adjust T...

Page 89: ... the engine should have adequate compres sion 1 Start the engine and let it warm up for several minutes 2 Remove Left side panel Right center panel Refer to GENERAL CHASSIS on page 4 1 3 Install Digital tachometer onto the spark plug lead of cylinder 1 4 Check Engine idling speed Out of specification Adjust 5 Adjust Engine idling speed a Turn the idling speed adjusting screw 1 in direction a or b ...

Page 90: ...e Bottom cowling Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Spark plug cap 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace th...

Page 91: ...om falling into the cylinders 6 Install Compression gauge 1 7 Measure Compression pressure Out of specification Refer to steps c and d a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pressure is...

Page 92: ...herefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again TIP Befor...

Page 93: ...CA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Check Engine oil drain bolt gasket Damage Replace 7 Install Engine oil drain bolt along with the gasket 8 Fill Crankcase with the specified amount of the recom mended engine oil 9 Install Engine oil filler cap Oil fil...

Page 94: ...again f Tighten the oil check bolt to specification g Install the bottom cowling Refer to GENER AL CHASSIS on page 4 1 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will h...

Page 95: ...ver make sure that the sealing sur faces are aligned to prevent any air leaks 5 Install Front lower inner panel Refer to GENERAL CHASSIS on page 4 1 EAS4B51007 REPLACING THE V BELT 1 Remove Right footrest board Refer to GENERAL CHASSIS on page 4 1 Outer V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 35 2 Check V belt Cranks damage wear Replace Grease oil Clean the primary and second...

Page 96: ...elt case air filter elements Damage Replace NOTICE ECA13440 Since the V belt case air filter element is a dry type do not let grease or water contact it 6 Install V belt case air filter element right V belt case air filter case V belt case air filter case cover 7 Install V belt case air filter element left EAS21010 CHECKING THE THROTTLE BODY JOINTS 1 Remove Front lower inner panel Refer to GENERAL...

Page 97: ...efer to GENERAL CHASSIS on page 4 1 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Footrest boards Refer to GENERAL CHASSIS on page 4 1 2 Check Cylinder head breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly 3 Install Footrest boards Refer to GENERAL CHASSIS on page 4 1 EAS21080 CHECKING...

Page 98: ...3470 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checkin...

Page 99: ...om cowling Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Coolant reservoir hose 1 3 Drain Coolant from the coolant reservoir 4 Remove Radiator cap 1 WARNING EWA4B51001 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may 1 2 3 4 7 5 2 6 11 10 3 8 9 4 1 ...

Page 100: ...nsult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention NOTICE ECA13480 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use o...

Page 101: ...m it up for several min utes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 17 TIP Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Bottom cowling Refer to GENERAL CHASSIS on page 4 1 a ...

Page 102: ...he brake lever a While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position TIP Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever WARNING EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bl...

Page 103: ...ately TIP 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 FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator groove a has almost disap peared Replace the brake pads as a set Refer to FRONT BRAKE on page 4 18 EAS21260 CHEC...

Page 104: ...lock cable length a a Slowly apply the rear brake several times b Turn the adjusting nut 1 in direction b or c until the rear brake lock cable length a is 42 44 mm 1 65 1 73 in when the rear brake lock lever is released c Set the rear brake lock lever and wait more than 5 minutes d Release the rear brake lock lever e Turn the adjusting nut 1 in direction b or c until the rear brake lock cable leng...

Page 105: ... will release the pres sure and cause the brake lever to contact the throttle grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake master cylinder reservoir to the proper level with the recommended brake flu id Refer to...

Page 106: ...il filler cap 2 4 Drain Chain drive oil completely from the chain drive case 5 Check Drain bolt gasket Damage Replace 6 Install Chain drive oil drain bolt along with the gasket 7 Fill Chain drive oil with the specified amount of the recom mended chain drive oil 8 Check Chain drive oil level Refer to CHECKING THE CHAIN DRIVE OIL LEVEL on page 3 24 9 Install Chain drive oil filler cap EAS21500 CHECK...

Page 107: ...d check the upper and lower bearings Refer to STEERING HEAD on page 4 58 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring ...

Page 108: ...WA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 49 EAS21650 CHECKI...

Page 109: ...res listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33...

Page 110: ...e the cable to corrode and interfere with its movement Replace damaged outer cable and inner ca bles as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal...

Page 111: ...nstall Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 I...

Page 112: ...EM 3 31 Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right 1 1 a b a b ...

Page 113: ...ALIPERS 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 CYLINDER 4 28 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 28 REAR BRAKE 4 30 INTRODUCTION 4 36 ...

Page 114: ...ET 4 60 CHECKING THE STEERING HEAD 4 60 INSTALLING THE STEERING HEAD 4 61 REAR SHOCK ABSORBER ASSEMBLY 4 62 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 SWINGARM AND TRANSMISSION CHAIN DRIVE 4 65 CHECKING THE SWINGARM 4 69 C...

Page 115: ......

Page 116: ...anel 1 3 Front upper inner panel 1 4 Battery cover 1 5 Battery holder 1 6 Negative battery lead 1 Disconnect 7 Positive battery lead 1 Disconnect 8 Battery 1 9 Windshield 1 10 Windshield bracket upper cover 1 For installation reverse the removal proce dure 4 6 8 7 10 1 1 9 3 2 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 117: ...rks 1 Footrest board mat 2 2 Footrest board cover 2 3 Side panel 2 4 Left side cowling 1 5 Bottom panel 1 6 Right side cowling 1 7 Wire harness to ignition coil 1 Unhook 8 Bottom cowling 1 For installation reverse the removal proce dure 5 6 8 4 3 2 3 1 2 7 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 118: ...er outer panel 1 2 Front lower inner panel 1 3 Center panel 2 4 Fuel tank overflow hose 1 Unhook 5 Rear brake pipe 1 Unhook 6 Left footrest board 1 7 Fuel tank breather hose 1 Unhook 8 Right footrest board 1 For installation reverse the removal proce dure 1 3 8 7 2 4 5 3 6 T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 119: ...indshield bracket lower cover 1 3 Meter ring 1 4 Meter assembly cover 1 5 Meter assembly coupler 1 Disconnect 6 Meter assembly 1 7 Storage compartment 1 8 Headlight sub wire harness coupler 2 Disconnect 9 Front cowling assembly 1 For installation reverse the removal proce dure 8 8 9 5 7 2 1 3 4 6 T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 120: ... bar 2 3 Rear cover 1 4 O2 sensor lead 1 Unhook 5 Taillight assembly coupler 1 Disconnect 6 Rear cowling assembly 1 7 Fuel tank cover 1 For installation reverse the removal proce dure 1 2 2 3 4 6 5 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib ...

Page 121: ...ver 1 7 Fuel pump coupler 1 Disconnect 8 Fuel hose connector cover 1 9 Fuel hose 1 Disconnect 10 Fuel tank overflow hose 1 11 Storage box inner mat 1 12 Seat lock 1 13 Seat hinge housing 1 14 Storage box light sub wire harness coupler 1 Disconnect 15 Storage box 1 For installation reverse the removal proce dure 15 12 11 14 6 2 1 3 13 4 5 10 7 8 9 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 f...

Page 122: ...onnector Disconnect the con nector from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed EAS4B51011 INSTALLING THE FUEL HOSE 1 Install Fuel hose Fuel hose connector cover NOTICE ECA4B51021 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover is in the correct posi tion otherwise the fuel h...

Page 123: ...4 Front reflector bracket 2 5 Front wheel axle pinch bolt 1 Loosen 6 Front wheel axle 1 7 Front wheel 1 8 Speed sensor 1 9 Collar 1 10 Wheel ring 1 11 Front brake disc 2 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R 1...

Page 124: ... Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R 18 Nm 1 8 m kg 13 ft Ib 6 6 8 11 7 11 10 5 1 2 3 4 6 2 4 3 9 LT 1 12 LT LT ...

Page 125: ...FRONT WHEEL 4 10 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Collar 1 For assembly reverse the disassembly pro cedure New 3 2 2 1 LS ...

Page 126: ... wheel hub b Remove the oil seal 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tir...

Page 127: ...tches the diameter of the wheel bearing outer race and oil seal EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP 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 TIP Place the front wheel on a suitable balancing stand a Spin th...

Page 128: ...n install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS21990 INSTALLING THE FRONT WHEEL DISC 1 Install Front brake discs TIP Tighten the brake disc bolts in stages and in a crissc...

Page 129: ...hten Front wheel axle Front wheel axle pinch bolt NOTICE ECA4B51005 Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly 7 Install Front brake calipers WARNING EWA13490 Make sure the brake cable is routed properly T R Front wheel axle 72 Nm 7 2 m kg 52 ft lb Front wheel axle pinch bolt 20 Nm 2 0 m kg 14 ft lb T R Front brake c...

Page 130: ...caliper 1 2 Transmission chain drive case cover 1 3 Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut 1 5 Rear wheel axle 1 6 Collar 1 7 Rear wheel 1 8 Rear brake disc 1 9 Spacer 1 For installation reverse the removal proce dure LT T R 7 Nm 0 7 m kg 5 1 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib 1 3 5 6 7 8 6 9 2 T R 40 Nm 4 0 m kg 29 ft Ib 4 T R 105 Nm 10 5 m kg 75 ft l...

Page 131: ...bling the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel drive hub 1 2 O ring 1 3 Oil seal 1 4 Wheel bearing 2 For assembly reverse the disassembly pro cedure 69 Nm 6 9 m kg 50 ft Ib LT LS LS LS New 3 4 4 1 2 4 ...

Page 132: ... 11 EAS4B51012 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage Replace EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust 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 W...

Page 133: ... both of the front brake calipers 1 Front brake hose holder bolt 1 2 Front brake caliper bolt 2 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 2 5 4 3 7 6 1 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib ...

Page 134: ...nder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Front brake hose 1 8 Brake hose gasket 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal proce dure 1 4 5 3 2 6 T R 6 Nm 0 6 m k...

Page 135: ...BRAKE 4 20 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 ...

Page 136: ...id Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Front brake hose holder bolt 1 2 Brake hose union bolt 1 3 Brake hose gasket 2 4 Front brake hose 1 5 Front brake caliper bolt 2 6 Front brake caliper 1 For installation reverse the removal proce dure 5 T R 40 Nm 4 0 m kg 29 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 1 2 3 4 6 New T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 137: ...nt 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 dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure BF 2 7 S BF BF New 6 6 5 5 6 6 7 New New New New New BF S S S 1 4 3 8 T R 5 Nm 0 5 m kg 3 6 ft Ib ...

Page 138: ...o both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to e...

Page 139: ...a Out of specification Replace the brake pads as a set 2 Install Front brake pads Brake pad spring TIP Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bl...

Page 140: ...Front brake hose holder bolt 1 Brake hose union bolt 2 Brake hose gaskets 3 Front brake hose 4 TIP 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 dust seals 2 Brake caliper piston seals 3 a Blow co...

Page 141: ... or new brake fluid Never use solvents on internal brake com ponents as they will cause the brake caliper piston dust seals and piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper...

Page 142: ...gnificantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE 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 23 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper le...

Page 143: ...1 Install Brake master cylinder 1 Brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark a facing up Align the end of the brake master cylinder hold er with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 2 Install Brake hose gaskets 1 Front brake hose 2 Brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is es...

Page 144: ...s not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE 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 23 5 Check Brake fluid level Below the minimu...

Page 145: ...Remarks 1 Rear brake caliper retaining bolt rear 1 2 Rear brake caliper bolt 2 3 Rear brake caliper 1 4 Rear brake pad 2 5 Brake pad support 2 6 Rear brake caliper bracket 1 For installation reverse the removal proce dure S S T R 40 Nm 4 0 m kg 29 ft Ib T R 31 Nm 3 1 m kg 22 ft Ib 5 4 1 5 2 6 2 3 ...

Page 146: ...linder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Rear brake hose 1 8 Brake hose gasket 2 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 For installation reverse the removal proce dure S 1 4 5 3 2 6 T R 6 Nm 0 6 m kg ...

Page 147: ...BRAKE 4 32 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 ...

Page 148: ...able 1 3 Pin 1 4 Spring 1 5 Rear brake lock cable holder 1 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Rear brake hose 1 9 Rear brake caliper retaining bolt 2 10 Rear brake caliper 1 11 Rear brake pad 2 12 Brake pad support 2 13 Rear brake caliper bolt 2 New 12 11 12 13 13 T R 40 Nm 4 0 m kg 29 ft Ib 14 3 4 10 1 2 8 7 7 5 6 S S T R 22 Nm 2 2 m kg 16 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 31 N...

Page 149: ... reverse the removal proce dure Removing the rear brake caliper Order Job Parts to remove Q ty Remarks New 12 11 12 13 13 T R 40 Nm 4 0 m kg 29 ft Ib 14 3 4 10 1 2 8 7 7 5 6 S S T R 22 Nm 2 2 m kg 16 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 31 Nm 3 1 m kg 22 ft Ib 9 9 ...

Page 150: ...Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 For assembly reverse the disassembly pro cedure 4 5 2 1 New 3 New T R 6 Nm 0 6 m kg 4 3 ft Ib S BF ...

Page 151: ... REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 15 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 Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace...

Page 152: ...he bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and then turn the brake caliper piston 3 clockwise until sec tion a of the brake caliper piston is level with the surface of the brake caliper body TIP Align the recesses b in the brake caliper piston with the brake caliper body as shown in the illus tration Brake pad lining thickness in ner 8 0 mm 0 31 ...

Page 153: ...AKE FLUID LEVEL on page 3 21 9 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake lock cable adjusting nut 1 Rear brake lock cable 2 Pin 3 Spring 4 Brake hose unio...

Page 154: ... 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA4B51009 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and piston seal 2 Check Brake caliper bracket 1 Cracks damage Replace Recommended br...

Page 155: ...R 1 Install Rear brake caliper bracket Rear brake caliper 1 temporarily Brake hose gaskets Rear brake hose 2 Brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 35 NOTICE ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake cali...

Page 156: ...mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 8 Install Rear brake lock cable holder Spring Pin Rear brake lock cable Rear brake lock cable adjusting nut 9 Check Rear brake lock cable length Refer to...

Page 157: ...se union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 35 NOTICE ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown TIP Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts e g wire ...

Page 158: ...s 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 23 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Re...

Page 159: ... Front brake master cylinder holder 1 8 Front brake master cylinder assembly 1 9 Rear brake light switch connector 2 Disconnect 10 Rear brake lock lever holder 1 1 11 Rear brake lock cable 1 Disconnect 12 Left handlebar switch 1 13 Rear brake master cylinder holder 1 14 Rear brake master cylinder assembly 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 2...

Page 160: ...verse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LS LS LS 1 1 4 4 6 2 8 14 12 15 2 10 11 10 12 9 16 5 7 3 13 1 17 ...

Page 161: ...tch lead 2 and rear brake hose 3 through the opening a in the handlebar Re fer to CABLE ROUTING on page 2 35 3 Install Lower handlebar cover TIP Route the throttle cables 1 and rear brake lock cable 2 through the lower handlebar cover 4 Install Handlebar grip a Apply a thin coat of a rubber adhesive to the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wi...

Page 162: ...h the UP mark a facing up Align the end of the brake master cylinder hold er with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 9 Install Throttle grip 1 Throttle cables 2 TIP Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 10 Install Right handlebar switch 1 WARNING EWA13720 Make sure th...

Page 163: ...HANDLEBAR 4 48 12 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 23 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 164: ... GENERAL CHASSIS on page 4 1 Front wheel Front fender Refer to FRONT WHEEL on page 4 8 1 Lower bracket cover bolt 2 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure LT 1 3 4 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 2 ...

Page 165: ...t 1 2 O ring 1 3 Spacer 1 4 Fork spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Inner tube bushing 1 1 2 3 4 5 10 11 12 16 6 7 13 14 15 17 18 9 8 New LT New New New New New New T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 166: ...18 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 1 2 3 4 5 10 11 12 16 6 7 13 14 15 17 18 9 8 New LT New New New New New New T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 167: ...ap bolt 2 Lower bracket pinch bolts 3 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a ...

Page 168: ...front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper 2 Damage Replace NOTICE ECA4B51006 When d...

Page 169: ... careful not to damage the inner tube 2 Install Oil flow stopper 1 3 Lubricate Inner tube s outer surface 2 4 Install Inner tube into the outer tube Copper washer Damper rod bolt 5 Tighten Damper rod bolt 1 TIP While holding the damper rod with the damper rod holder 2 and T handle 3 tighten the damper rod bolt 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver weight 3 and fork seal...

Page 170: ... installation 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver weight 2 10 Fill Front fork leg with the specified amount of the recom mended fork oil NOTICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembli...

Page 171: ...Out of specification Correct 14 Install Fork spring Fork spring seat Spacer Cap bolt along with the O ring TIP Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP ...

Page 172: ...FRONT FORK 4 57 2 3 ...

Page 173: ...efer to FRONT FORK on page 4 49 Handlebar Refer to HANDLEBAR on page 4 44 1 Steering stem nut 1 2 Upper bracket 1 3 Lock washer 1 4 Upper ring nut 1 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 8 Upper bearing cover 1 9 Upper bearing inner race 1 10 Upper bearing 1 11 Lower bearing 1 T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb final 14 Nm 1 4 m kg 10 ft lb LS LS LS 1 2 ...

Page 174: ... race 1 15 Upper bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb final 14 Nm 1 4 m kg 10 ft lb LS LS LS 1 2 3 4 5 6 8 14 11 12 13 7 9 10 15 ...

Page 175: ...D 1 Wash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and new bearing races NOTICE ECA14270 If the bearing race is not installed pro...

Page 176: ... 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 25 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 49 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease T R Steer...

Page 177: ...bly Refer to ENGINE REMOVAL on page 5 1 1 Rear shock absorber assembly front bolt 1 2 Lock washer 1 3 Collar 1 4 Rear shock absorber assembly rear nut bolt 1 1 5 Rear shock absorber assembly 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 Bearing 2 For installation reverse the removal proce dure LS New 5 6 8 9 9 7 4 1 2 3 4 68 Nm 6 8 m kg 49 ft Ib 53 Nm 5 3 m kg 38 ft Ib LS LS ...

Page 178: ...k absorber at a point 10 14 mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the centerstand so that the rear wheel is elevat...

Page 179: ...sed grease 3 Tighten Rear shock absorber assembly rear nut 4 Tighten Rear shock absorber assembly front bolt 1 TIP Bend the lock washer 2 tab along a flat side of the bolt 1 T R Rear shock absorber assembly rear nut 53 Nm 5 3 m kg 38 ft lb T R Rear shock absorber assembly front bolt 68 Nm 6 8 m kg 49 ft lb 2 1 New ...

Page 180: ...ge 4 1 Rear wheel Refer to REAR WHEEL on page 4 15 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 62 1 Rear brake hose rear brake lock cable holder 1 2 Pivot shaft end cover 1 3 Pivot shaft nut 1 4 Washer 1 5 Swingarm 1 6 Dowel pin 2 7 Pivot shaft 1 8 Collar 1 15 T R 10 Nm 1 0 m kg 7 2 ft Ib 8 9 7 4 3 2 6 6 10 12 New New New LS LS LS T R 100 Nm 10 0 m kg 72 ft lb T R...

Page 181: ...e 1 For installation reverse the removal proce dure Removing the swingarm and transmission chain drive assembly Order Job Parts to remove Q ty Remarks 15 T R 10 Nm 1 0 m kg 7 2 ft Ib 8 9 7 4 3 2 6 6 10 12 New New New LS LS LS T R 100 Nm 10 0 m kg 72 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib 13 1...

Page 182: ... gear 1 3 Secondary drive chain 1 4 Secondary driven gear 1 5 Chain drive case gasket 1 6 Dowel pin 2 7 Middle shaft 1 8 Primary driven gear 1 9 Primary drive chain 1 10 Primary drive gear 1 11 Inner chain drive case 1 12 Oil seal 4 13 Bearing 5 14 Collar 1 New New New New New New 3 4 13 12 14 1 13 2 9 10 6 13 7 8 12 13 6 12 15 11 12 10 Nm 1 0 m kg 7 2 ft Ib 18 LS LS LS LS LS 5 ...

Page 183: ...ng retainer 1 For assembly reverse the disassembly pro cedure Disassembling the transmission chain drive assembly Order Job Parts to remove Q ty Remarks New New New New New New 3 4 13 12 14 1 13 2 9 10 6 13 7 8 12 13 6 12 15 11 12 10 Nm 1 0 m kg 7 2 ft Ib 18 LS LS LS LS LS 5 ...

Page 184: ...en gear 6 Damage wear Replace the respective gears and respective drive chain as a set EAS4B51018 ASSEMBLING THE TRANSMISSION CHAIN DRIVE ASSEMBLY 1 Install Outer chain drive case TIP First tighten the chain drive case bolts that are numbered in the illustration in the order shown and then tighten the unnumbered bolts in a crisscross pattern EAS4B51019 INSTALLING THE TRANSMISSION CHAIN DRIVE ASSEM...

Page 185: ...en Pivot shaft Pivot shaft nut a With your fingers screw in the pivot shaft until it touches the collar and then tighten the piv ot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque 5 Fill Transmission chain drive case Refer to CHANGING THE CHAIN DRIVE OIL on page 3 25 6 Check Chain drive oil level Refer to CHECKING THE CHAIN DRIVE OIL LEVEL on page 3 24 T R Swing...

Page 186: ...SWINGARM AND TRANSMISSION CHAIN DRIVE 4 71 ...

Page 187: ...ING THE CYLINDER HEAD 5 16 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 23 CHECKING THE VALVE LIFTERS 5 23 INSTALLING THE VALVES 5 23 CYLINDER AND PISTONS 5 26 REMOVING THE PISTONS 5 27 CHECKING THE CYLINDERS AND PISTONS 5 27 CHECKING THE PISTON RINGS 5 28 CHECKING THE PISTON PINS 5 29 IN...

Page 188: ...UTCH 5 51 CHECKING THE OIL STRAINER 5 51 INSTALLING THE STARTER CLUTCH 5 51 INSTALLING THE GENERATOR 5 52 CLUTCH 5 54 REMOVING THE CLUTCH 5 57 DISASSEMBLING THE CLUTCH 5 57 CHECKING THE FRICTION PLATES 5 58 CHECKING THE CLUTCH PLATES 5 58 CHECKING THE CLUTCH DAMPER SPRINGS 5 58 CHECKING THE CLUTCH SPRING PLATE 5 58 CHECKING THE CLUTCH SPRINGS 5 59 CHECKING THE CLUTCH HOUSING 5 59 CHECKING THE CLUT...

Page 189: ... THE CRANKSHAFT JOURNAL BEARINGS 5 73 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 73 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 5 76 INSTALLING THE CONNECTING RODS 5 77 INSTALLING THE CRANKSHAFT ASSEMBLY 5 78 TRANSMISSION 5 79 CHECKING THE TRANSMISSION 5 80 ...

Page 190: ...anel Refer to GENERAL CHASSIS on page 4 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 For installation reverse the removal proce dure LT LT 4 4 1 2 3 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 31 Nm 3 1 m kg 22 ft Ib New New LT LT ...

Page 191: ...N DRIVE OIL on page 3 25 Fuel tank Refer to FUEL TANK on page 7 1 Intake manifolds Refer to THROTTLE BODY on page 7 5 Radiator bracket Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Thermostat Refer to THERMOSTAT on page 6 7 Water pump assembly Refer to WATER PUMP on page 6 9 Rear wheel Refer to REAR WHEEL on page 4 15 Rear shock absorber assembly Refer to REAR SHOCK ABSO...

Page 192: ...plug cap 2 Disconnect 4 Plastic clamp 7 Open 5 Rear brake lock cable holder 1 6 Crankshaft position sensor coupler 1 Disconnect 7 Stator coil coupler 1 Disconnect 8 Sidestand switch coupler 1 Disconnect 9 Seat lock cable 1 10 Wire harness 1 For installation reverse the removal proce dure Disconnecting the leads Order Job Parts to remove Q ty Remarks 1 5 3 6 3 8 4 4 9 4 4 4 2 10 7 T R 30 Nm 3 0 m k...

Page 193: ...destand 1 9 Engine mounting bolt front right lower side 2 10 Washer 1 11 Engine mounting nut front upper side 1 12 Washer 1 13 Engine mounting bolt front upper side 1 14 Engine 1 For installation reverse the removal proce dure T R 45 Nm 4 5 m kg 32 ft Ib T R 105 Nm 10 5 m kg 75 ft lb T R 83 Nm 8 3 m kg 60 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 83 Nm 8 3 m kg 60 ft Ib 9 9...

Page 194: ... Engine mounting nut front upper side 4 Engine mounting bolts front right lower side 1 Engine mounting bolts front left lower side 2 Engine mounting nut rear side 5 Rear frame bolts 3 T R Engine mounting nut front upper side 88 Nm 8 8 m kg 64 ft lb Engine mounting bolt front right lower side 45 Nm 4 5 m kg 32 ft lb LOCTITE Engine mounting bolt front left lower side 45 Nm 4 5 m kg 32 ft lb LOCTITE ...

Page 195: ...e 4 1 Front wheel Front fender Refer to FRONT WHEEL on page 4 8 Radiator Refer to RADIATOR on page 6 1 Fuel tank Refer to FUEL TANK on page 7 1 Intake manifolds Refer to THROTTLE BODY on page 7 5 1 Spark plug 2 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Dowel pin 2 5 Gasket 2 6 Timing chain guide upper side 1 LS 1 10 2 6 5 4 4 8 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 13 Nm 1 3 m kg 9 4 ft...

Page 196: ...over 1 For installation reverse the removal proce dure Removing the cylinder head cover Order Job Parts to remove Q ty Remarks LS 1 10 2 6 5 4 4 8 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib New 3 New ...

Page 197: ...sioner gasket 1 4 Intake camshaft cap 1 5 Exhaust camshaft cap 1 6 Dowel pin 4 TIP During removal the dowel pins may still be connected to the camshaft caps 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure LS M M T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 5 8 6 7 6 6 2 3 6 6 1 4 New E T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 198: ...piston is at TDC the alignment hole c on the intake camshaft sprocket and the alignment hole d on the ex haust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 2 3 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 Dowel pins NOTICE ECA13720 To prevent damage to the cylinder head camshaf...

Page 199: ...a Install the camshaft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Intake A 33 252 33 352 mm 1 3091 1 3131 in Limit 33 152 mm 1 3052 in Intake B 24 956 25 056 mm 0 9825 0 9865 in Limit 24 856 mm 0 9786 in Exhaust A 33 252 33 352 mm 1 3091 1 3131 in Limit 33 152 mm 1 3052 in Exhaust B...

Page 200: ...fication Replace the cylinder head and the camshaft caps as a set EAS4B51035 CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the camshaft sprockets 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshafts and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide intake side 1 Timing chain guide exhaust side 2 Tim...

Page 201: ...in tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS24000 INSTALLING THE CAMSHAFTS 1 Install Exhaust camshaft 1 Intake camshaft 2 a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the I mark a on the gen erator rotor with the stationary pointer b on the generator cover c Install the timing chain onto both camshaft...

Page 202: ...ap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshafts will result 4 Install Timing chain tensioner gasket Timing chain tensioner a Push the timing chain tensioner rod 1 into the timing chain tensioner housing by hand TIP While pushing the timing chain tensioner rod a turn it clockwise b with the timing chain ten sioner body 2 until if stops b Lock the timing...

Page 203: ...ve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 8 Install Timing chain guide upper side Gaskets to the cylinder head cover TIP Apply Yamaha bond No 1215 1 onto the mat ing surface of the cylinder head cover and tim ing chain guide upper side Apply Yamaha bond No 1215 1 onto the mat ing surfaces of the cylinder head cover and gaskets 9 Install Cylinder h...

Page 204: ...on page 5 1 Thermostat Coolant temperature sensor Refer to THERMOSTAT on page 6 7 Coolant pipe Refer to OIL COOLER on page 6 4 Intake and exhaust camshafts Refer to CAMSHAFTS on page 5 6 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure New New E 1 2 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 46 Nm 4 6 m kg 33 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib ...

Page 205: ...der head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figur...

Page 206: ...head nuts and washers with engine oil Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head nut 35 Nm 3 5 m kg 25 ft lb T R Cylinder head nut 46 Nm 4 6 m kg 33 ft lb T R Cylinder head bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 207: ...s Cylinder head Refer to CYLINDER HEAD on page 5 15 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 For installation reverse the removal proce dure New New M M M M M M E E 1 2 3 4 5 8 9 1 2 3 4 5 8 9 10 6 7 10 ...

Page 208: ... 21 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring...

Page 209: ...uide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP 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 ...

Page 210: ...o all of the 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 a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 Valve guide installer ø4 90890 04112 ...

Page 211: ... 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 until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping c...

Page 212: ...ALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components Free length intake 35 59 mm 1 40 in Limit 33 81 mm 1 33 in Free length exhaust 35 59 mm 1 40 in Limit 33 81 mm 1 33 in Installed compress...

Page 213: ...ch valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Recommended lubricant Molybdenum disulfide oil b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compres...

Page 214: ...cant 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTICE ECA4B51016 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubric...

Page 215: ...r head Refer to CYLINDER HEAD on page 5 15 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Piston ring set 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal proce dure E 4 4 2 5 7 1 6 5 3 E T R 10 Nm 1 0 m kg 7 2 ft Ib New New New E 8 9 10 ...

Page 216: ...ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24400 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Pisto...

Page 217: ...place the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown b 9 0 mm 0 35 in from the bottom edge of the piston Piston Diameter D 65 965 65 980 mm 2 5970 2 5976 in Piston to cylinder ...

Page 218: ... piston pin bore clearance Out of specification Replace the piston pin and piston as a set EAS24470 INSTALLING THE PISTONS AND CYLINDER The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 2nd ring O ring Piston ring Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 40 0 50 mm 0 0157 0 0197 in Limit 0 75...

Page 219: ...ase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Install Dowel pins Cylinder gasket 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder TIP While compressing the piston rings install the cylinder Pass the timing chain...

Page 220: ...r Job Parts to remove Q ty Remarks Storage box Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Negative battery lead 1 2 Starter motor lead 1 3 Starter motor 1 For installation reverse the removal proce dure 1 2 3 T R 10 Nm 1 0 m kg 7 2 ft Ib LS New ...

Page 221: ...ver 1 2 Bearing 1 3 Oil seal 1 4 Circlip 1 5 Armature assembly 1 6 Starter motor yoke 1 7 O ring 2 8 Insulator 1 9 Brush 2 10 Brush spring 4 11 Brush holder 1 12 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure 1 12 11 10 10 9 9 8 3 5 7 6 7 2 4 New New New New New T R 11 Nm 1 1 m kg 8 0 ft Ib ...

Page 222: ...r b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brushes as a set 5 Measure Brush spring force Out of specification Replace the brush springs as a set 6 Check Gear teeth Damage wear Replace the armature as sembly EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Insulator 1 TIP Install the insulator so that the slot a ...

Page 223: ...ver 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers EAS24810 INSTALLING THE STARTER MOTOR 1 Connect Negative battery lead 1 TIP Make sure that the negative battery lead 1 does not touch the starter motor bolt 2 1 a a b b 1 2 3 2 1 ...

Page 224: ...n page 5 1 1 Right passenger footrest 1 2 Crankshaft end access cover 1 3 V belt case air filter case cover 1 4 V belt case air filter case 1 5 V belt case air filter element right 1 6 Rear brake lock cable holder 1 7 Outer V belt case 1 8 Outer V belt case gasket 1 9 Bearing retainer 1 10 Bearing 1 11 Circlip 1 New New LS 3 4 2 7 8 10 9 11 12 13 5 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg...

Page 225: ...oce dure Removing the V belt case cover Order Job Parts to remove Q ty Remarks New New LS 3 4 2 7 8 10 9 11 12 13 5 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib 4 6 E 3 6 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib LT 6 ...

Page 226: ...ut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 Dowel pin 2 14 Plate 1 7 6 5 1 3 2 8 9 10 15 13 13 14 12 4 1 11 3 1 2 New T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 90 Nm 9 0 m kg 65 ft Ib T R 160 Nm 16 0 m...

Page 227: ...tallation reverse the removal proce dure Removing the V belt and primary secondary sheave Order Job Parts to remove Q ty Remarks 7 6 5 1 3 2 8 9 10 15 13 13 14 12 4 1 11 3 1 2 New T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 90 Nm 9 0 m kg 65 ft Ib T R 160 Nm 16 0 m kg 115 ft lb 1 2 ...

Page 228: ...assembly lube Disassembling the primary sheave Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 4 3 Primary sheave weight 8 4 Primary sliding sheave 1 5 Collar 1 6 Oil seal 2 For assembly reverse the disassembly pro cedure 6 New New 4 3 5 1 2 6 ...

Page 229: ...ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Oil seal 2 9 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure 8 1 2 3 4 8 7 6 5 9 T R 90 Nm 9 0 m kg 65 ft Ib New New New ...

Page 230: ... the secondary fixed sheave 2 with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring seat nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave assembly as shown Then compress the spring and remove the second...

Page 231: ...the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS24700 CHECKING THE SLIDERS The following procedure applies to all of the slid ers 1 Check Slider Cracks damage wear Replace EAS24710 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage w...

Page 232: ...y fixed sheave inner surface 1 Secondary sliding sheave inner surface 2 Grease nipple groove Oil seals 2 Install Secondary sliding sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 3 Install Guide pins 1 4 Lubricate Guide pin groove 2 O rings 3 with the recommended lubricant 5 Install Secondary sheave spring seat nut 1 Recommended lubrica...

Page 233: ...EAS4B51024 INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 1 Apply Sealant onto the inner V belt case seal 2 Install V belt case air duct joint clamp 1 V belt case air duct 2 TIP Align the projection a in the V belt case air duct 2 with the slot b on the V belt case air duct joint clamp 1 Align the projection c in the V belt case air duct 2 with the slot d in the inner ...

Page 234: ... Tighten Secondary sheave nut 1 TIP While holding the secondary sheave with the sheave holder 2 tighten the secondary sheave nut 5 Tighten Primary sheave nut 1 NOTICE ECA4B51022 Before tightening the nut to remount the primary sheave make sure that the serra tions of the cam are fitted firmly into the serrations of the crankshaft Also make sure that cam is properly seat ed Apply grease to the thre...

Page 235: ...lustration with 10 g or more of lithium soap based grease 3 Install Bearing retainer 1 TIP Install each bearing retainer 1 with its mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer bolt Installed depth of oil seal a 4 0 4 3 mm 0 16 0 17 in T R Bearing retainer bolt 11 Nm 1 1 m kg 8 0 ft lb LOCTITE 2 1 b a 1 1 a ...

Page 236: ...CHANGING THE ENGINE OIL on page 3 12 Water pump assembly Refer to WATER PUMP on page 6 9 1 V belt case air duct 1 2 Left passenger footrest 1 3 Crankshaft position sensor coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Generator cover 1 6 Generator cover gasket 1 7 Dowel pin 2 8 Starter clutch idle gear shaft 1 LT E E E E 16 15 13 8 12 11 10 7 6 7 3 5 2 4 14 19 1 9 T R 30 Nm 3 0 m kg 22 ...

Page 237: ...gear 1 16 Washer 1 For installation reverse the removal proce dure Removing the generator rotor and starter clutch Order Job Parts to remove Q ty Remarks LT E E E E 16 15 13 8 12 11 10 7 6 7 3 5 2 4 14 19 1 9 T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 65 Nm 6 5 m kg 47 ft lb final Specified angle 120 T R 30 Nm 3 0 m kg 22 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 238: ...emove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 For installation reverse the removal proce dure IN LT LT New E 6 4 3 2 1 3 7 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 239: ...he projection on the generator rotor 3 Remove Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the ...

Page 240: ...h and the start er clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter c...

Page 241: ...1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor NOTICE ECA4B51018 When tightening the generator rotor nut be sure to use a beam type torque wrench Tighten the nut until it is at the specified an gle 3 Apply Sealant onto the crankshaft position sensor lead grommet 4 Insta...

Page 242: ...GENERATOR AND STARTER CLUTCH 5 53 TIP Tighten the generator cover bolts in stages and in a crisscross pattern T R Generator cover bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 243: ...tch Order Job Parts to remove Q ty Remarks Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 47 1 Clutch assembly nut 1 2 Clutch assembly 1 3 Washer 1 For installation reverse the removal proce dure 1 2 3 T R 65 Nm 6 5 m kg 47 ft Ib ...

Page 244: ...ssure plate 2 5 Clutch plate 2 2 6 Clutch damper spring 6 7 Friction plate 5 8 Clutch plate 1 4 9 Clutch spring 6 10 Clutch boss nut 1 11 Primary drive gear 1 12 Bearing 2 13 Clutch boss 1 14 Collar 1 15 Thrust plate 1 16 Clutch weight 12 16 14 15 13 10 1 2 3 4 5 6 7 8 6 11 12 4 9 6 6 12 E 7 5 7 8 7 8 7 8 6 E T R 130 Nm 13 0 m kg 94 ft lb 17 ...

Page 245: ...ousing 1 For assembly reverse the disassembly pro cedure Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 14 15 13 10 1 2 3 4 5 6 7 8 6 11 12 4 9 6 6 12 E 7 5 7 8 7 8 7 8 6 E T R 130 Nm 13 0 m kg 94 ft lb 17 ...

Page 246: ...ip 2 Remove Spring stopper plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its original position 3 Loosen Clutch boss nut 1 TIP While holding the clutch b...

Page 247: ...utch plates as a set EAS4B51027 CHECKING THE CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch damper springs 1 Check Clutch damper spring Damage Replace 2 Measure Clutch damper spring free height a Out of specification Replace the clutch damper springs as a set EAS25130 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate Damage Replace 2 Measure Clutch spring pla...

Page 248: ...utch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace EAS4B51029 A...

Page 249: ...hrust plate 1 Clutch springs Clutch damper springs 2 Clutch plates 2 3 Friction plates 4 Clutch plates 1 5 Pressure plate 6 Clutch spring plate 7 6 Install Circlip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the circlip EAS25240 INSTALLING THE CLUTCH 1 Install Clutch assembly 1 Clutch assembly nut 2 Recommended lubricant Engine oil T R Clutch boss nut 130...

Page 250: ... during reassembly While holding the clutch assembly with the ro tor holding tool 3 tighten the clutch assembly nut T R Clutch assembly nut 65 Nm 6 5 m kg 47 ft lb Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 ...

Page 251: ... Refer to GENERATOR AND STARTER CLUTCH on page 5 47 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Gasket 2 4 Oil delivery pipe 1 5 Oil pipe 1 6 Relief valve assembly 1 For installation reverse the removal proce dure LS LS LS 6 5 4 1 2 3 3 LS New New LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 252: ...Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1 11 Oil pump driven gear 1 12 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure E E 1 2 4 3 5 11 12 10 8 9 7 6 E ...

Page 253: ...VALVE 1 Check Relief valve body Damage wear Replace EAS4B51030 CHECKING THE OIL PIPES 1 Check Oil pipe Oil delivery pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS4B51031 CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump driven sprocket as a set 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner roto...

Page 254: ...er rotor align the pin 1 in the oil pump shaft with the groove a in the in ner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 64 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly Recommended lubricant Engine oil T R Oil pump bolt 10 Nm 1 0 m kg 7 2 ft lb 1 a 1 a ...

Page 255: ...n page 5 47 Clutch assembly Refer to CLUTCH on page 5 54 Oil pump assembly Refer to OIL PUMP on page 5 62 Inner V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 35 1 Centerstand assembly 1 2 Timing chain 1 3 Timing chain guide intake side 1 4 Left crankcase 1 5 Dowel pin 2 6 Oil strainer 1 5 4 7 5 8 8 4 4 5 1 3 6 2 LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R ...

Page 256: ... dure Separating the crankcase Order Job Parts to remove Q ty Remarks 5 4 7 5 8 8 4 4 5 1 3 6 2 LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 257: ...rts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 71 Transmission Refer to TRANSMISSION on page 5 79 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 For installation reverse the removal proce dure 2 1 2 3 3 3 T R 12 Nm 1 2 m kg 8 7 ft Ib LT ...

Page 258: ...aces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS4B51032 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain and camshafts as a set EAS25700 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply Sealant onto the...

Page 259: ...CRANKCASE 5 70 M6 35 mm bolts 3 5 Check Crankshaft and transmission operation Rough movement Repair 1 2 2 1 3 3 2 1 ...

Page 260: ...ts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Dowel pin 2 2 Crankshaft assembly 1 3 Balancer cylinder 1 4 Oil seal 1 5 Crankshaft journal bearing 2 For installation reverse the removal proce dure 1 2 3 5 5 4 4 LT T R 58 Nm 5 8 m kg 42 ft Ib E E E E E ...

Page 261: ...piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 For installation reverse the removal proce dure E E M E E E E E E 5 10 11 6 7 1 2 1 2 New New 5 New New M M M M M M M M T R 60 Nm 6 0 m kg 43 ft Ib 4 4 9 8 3 3 T R 1st 16 Nm 1 6 m kg 11 ft lb Specified angle 90 New New New T R 1st 16 Nm 1 6 m kg 11 ft lb Spec...

Page 262: ...haft main journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place EAS26090 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaf...

Page 263: ...ble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolts threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned e Tighten the...

Page 264: ...al positions NOTICE ECA4B51026 On the journal the larger value is used as a basis for calculation of the oil clearance and on the journal bearing the smaller value is used a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Check the bearing surface If the bearing sur face is worn or scratched both bearings should be replaced TIP If either of the ri...

Page 265: ...J1 and the crankshaft web J1 numbers are 4 and 2 re spectively then the bearing size for J1 is EAS25630 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS The following procedure applies to both of the crankshaft main journal bearings 1 Attach Crankshaft journal bearing 1 TIP Attach the crankshaft journal bearing to the plane bearing installer 2 2 Install Crankshaft journal bearing TIP Align the projectio...

Page 266: ...riginal place Make sure the Y marks c on the connecting rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod nuts WARNING EWA13390 Replace the connecting rod bolts and nuts with new ones Clean the connecting rod bolts and nuts TIP Tighten the connecting rod bolts using the fol lowing pr...

Page 267: ... beam type torque wrench Tighten the nuts to the specified torque Apply continuous torque between 30 Nm 3 0 m kg 22 ft lb and 60 Nm 6 0 m kg 43 ft lb without pausing After reaching 30 Nm 3 0 m kg 22 ft lb DO NOT STOP TIGHT ENING until the specified torque is achieved If the tightening is interrupted be tween 30 Nm 3 0 m kg 22 ft lb and 60 Nm 6 0 m kg 43 ft lb loosen the nut to less than 30 Nm 3 0 ...

Page 268: ...move Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Secondary shaft 1 2 Collar 1 3 Primary driven gear 1 4 Main axle 1 5 1st pinion gear 1 6 Drive axle 1 7 1st wheel gear 1 8 Circlip 1 For installation reverse the removal proce dure 7 8 6 3 4 5 1 2 3 4 5 New E E E E LS ...

Page 269: ...ge Out of specification Replace the drive axle 3 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the second ary shaft 4 Check Transmission gear movement Rough movement Replace the defective part s 5 Check Circlips Bends damage looseness Replace Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Maximum secondary sha...

Page 270: ...TRANSMISSION 5 81 ...

Page 271: ...COOLER 6 4 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 272: ... 2 Coolant reservoir 1 3 Radiator cap 1 4 Cooling system air bleed hose 1 5 Radiator filler pipe 1 6 Radiator filler hose 1 7 Radiator inlet hose 1 8 Fast idle plunger outlet coolant hose 1 Disconnect 9 Radiator outlet hose 1 Disconnect 10 Radiator fan motor coupler 1 Disconnect 11 Radiator guard 1 12 Radiator 1 1 2 3 13 10 6 5 12 11 14 7 8 9 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft ...

Page 273: ...ator bracket 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks 1 2 3 13 10 6 5 12 11 14 7 8 9 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 274: ...nd make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 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 18 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure B...

Page 275: ... Refer to CHANGING THE ENGINE OIL on page 3 12 Coolant Drain Refer to CHANGING THE COOLANT on page 3 18 1 Oil filter cartridge 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Radiator inlet hose 1 Disconnect 5 Thermostat outlet hose 1 6 Coolant pipe 1 7 Oil filter cartridge union bolt 1 1 2 5 6 3 4 7 8 New E E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib T R 17 Nm 1 7 m kg 12 ...

Page 276: ...ler 1 For installation reverse the removal proce dure Removing the oil cooler Order Job Parts to remove Q ty Remarks 1 2 5 6 3 4 7 8 New E E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib ...

Page 277: ...rojection a on the oil cooler with the slot b in the crankcase 3 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 12 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 12 5 Check Cooling system Leaks...

Page 278: ... page 3 18 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Copper washer 1 4 Cooling system air bleed hose 1 Disconnect 5 Thermostat outlet hose 1 Disconnect 6 Thermostat cover 1 7 Thermostat 1 8 Fast idle plunger inlet coolant hose 1 Disconnect 9 Coolant hose 1 Disconnect For installation reverse the removal proce dure 3 2 5 6 7 8 4 1 New T R 10 Nm 1 0 m kg 7 2 ...

Page 279: ...A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing forward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 3 Check Cooling system Leaks Repair...

Page 280: ...int clamp screw 1 Loosen 2 V belt case air filter element left 1 3 Generator cover protector cover 1 4 Generator cover protector 1 5 Oil cooler inlet hose 1 Disconnect 6 Coolant hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 10 Water pump assembly 1 For installation reverse the removal proce dure 1 4 3 2 10 8 7 9 5 6 10 Nm 1 0 m kg 7 2 ft...

Page 281: ...el is extremely low or coolant contains engine oil 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Bearing 1 9 Oil seal 1 10 Water pump housing 1 For assembly reverse the disassembly pro cedure 10 3 8 2 4 1 9 New New M 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 282: ...Water pump housing Impeller shaft Water pump seal Oil seal Rubber damper Rubber damper holder Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS26570 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil sea...

Page 283: ... Align the projection a on the oil pump shaft and water pump shaft groove b Lubricate the O ring with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver ...

Page 284: ...UMP 6 13 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 285: ...NG THE FUEL PUMP 7 3 CHECKING THE FUEL PUMP BODY 7 3 CHECKING THE ROLLOVER VALVE 7 3 INSTALLING THE FUEL PUMP 7 3 CHECKING THE FUEL PRESSURE 7 3 THROTTLE BODY 7 5 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODY 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 ...

Page 286: ...s Storage box Refer to GENERAL CHASSIS on page 4 1 1 Fuel tank breather hose 2 2 Rollover valve 1 3 Fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump 1 6 Fuel pump gasket 1 For installation reverse the removal proce dure 1 4 5 3 2 6 1 T R 10 Nm 1 0 m kg 7 2 ft Ib 6 4 T R 4 Nm 0 4 m kg 2 9 ft Ib New ...

Page 287: ... GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Fuel tank breather hose 1 2 Canister purge hose 3 way joint to canister 1 3 Canister purge hose throttle body to 3 way joint 2 4 Canister 1 For installation reverse the removal proce dure 4 3 2 3 1 T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 288: ...the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Align projection a on the fuel pump with point b of the fuel tank Tighten the fuel pump bolts in the proper tight ening sequence as shown EAS27010 CHECKING THE FUEL PRESSURE 1 Check Pressure regulator operation a Remove the fuel hose connect...

Page 289: ... Faulty Replace the fuel pump e Set the main switch to OFF f Remove the pressure gauge and fuel pres sure adapter TIP Before removing the special tools place a few rags in the area under where they will be re moved Pressure gauge 90890 03153 YU 03153 Fuel pressure adapter 90890 03181 Output pressure 246 0 254 0 kPa 35 7 36 8 psi 2 46 2 54 kgf cm 1 2 1 3 2 ...

Page 290: ...nect 2 Intake air temperature sensor 1 3 Cylinder head breather hose 1 4 Fast idle plunger intake hose 1 5 Air filter case joint clamp screw 2 Loosen 6 Air filter case 1 7 Throttle cable 2 8 Fast idle plunger outlet coolant hose 1 9 Fast idle plunger inlet coolant hose 1 10 Throttle position sensor coupler 1 Disconnect 11 Throttle body joint clamp screw 2 Loosen 2 1 3 4 5 5 13 10 7 7 8 12 9 11 11 ...

Page 291: ...jector 2 1 19 Intake air pressure sensor hose 1 20 Intake manifold 1 1 21 Intake manifold 2 1 For installation reverse the removal proce dure Removing the throttle body assembly Order Job Parts to remove Q ty Remarks 2 1 3 4 5 5 13 10 7 7 8 12 9 11 11 19 20 21 4 17 18 14 16 13 15 6 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS E New New E ...

Page 292: ...bling the throttle body as sembly make sure to note the number of times the air screw is turned out from the seated position to its set position 1 Throttle position sensor 1 2 Fast idle plunger 1 3 Idling speed adjusting screw 1 4 Air screw 2 For assembly reverse the disassembly pro cedure 1 3 4 4 2 2 New New New New ...

Page 293: ...hrottle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 77 2 Adjust Throttle position sensor angle a Connect the throttle position sensor coupler b Connect the pocket tester AC 20 V to the throttle position sensor coupler as shown c Turn the main switch to ON d Measure the throttle position sensor output voltage e Adjust the throttle position sensor angle so that the outp...

Page 294: ...THROTTLE BODY 7 9 ...

Page 295: ... 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 SELF DIAGNOSTIC FUNCTION TABLE 8 32 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 35 TROUBLESHOOTING DETAILS 8 40 FUEL PUMP...

Page 296: ...THE IGNITION SPARK GAP 8 72 CHECKING THE CRANKSHAFT POSITION SENSOR 8 72 CHECKING THE LEAN ANGLE SENSOR 8 73 CHECKING THE STARTER MOTOR OPERATION 8 73 CHECKING THE STATOR COIL 8 74 CHECKING THE RECTIFIER REGULATOR 8 74 CHECKING THE HORN 8 75 CHECKING THE FUEL SENDER 8 75 CHECKING THE SPEED SENSOR 8 76 CHECKING THE RADIATOR FAN MOTOR 8 76 CHECKING THE COOLANT TEMPERATURE SENSOR 8 76 CHECKING THE TH...

Page 297: ......

Page 298: ... L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O B...

Page 299: ...STEM 8 2 1 Crankshaft position sensor 4 Main switch 11 Ignition fuse 14 Battery 15 Main fuse 20 Engine stop switch 28 Sidestand switch 29 ECU engine control unit 30 Ignition coil 31 Spark plug 39 Lean angle sensor ...

Page 300: ...he battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 72 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 71 Replace the spark plug caps 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page...

Page 301: ... 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the sidestand switch 11 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 73 Replace the lean angle sensor 12 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem wiring Replace the ECU engine control unit ...

Page 302: ...W G R Y B L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R ...

Page 303: ... system fuse 11 Ignition fuse 14 Battery 15 Main fuse 16 Starter relay 17 Starter motor 18 Diode 1 20 Engine stop switch 21 Start switch 22 Front brake light switch 23 Diode 2 24 Starting circuit cut off relay 28 Sidestand switch 57 Rear brake light switch ...

Page 304: ...tand switch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at lea...

Page 305: ...3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Diode 2 7 Starting circuit cut off relay 8 Sidestand switch 9 Signaling system fuse 10 Front brake light switch 11 Rear brake light switch 12 Start switch 13 Diode 1 14 Starter relay 15 Starter motor ...

Page 306: ...rminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 73 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 33 Repair or replace the starter motor 5 Check the diode 1 Refer to CHECKING THE DIODE on page 8 ...

Page 307: ...age 8 61 Replace the sidestand switch 11 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the front brake light switch 12 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the rear brake light switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 61 The start switch is faulty Replace the right handlebar s...

Page 308: ... W BLACK W W L W B BLACK L Y R B L G R G R L G B B R L G G W G Y L Y Lg B Gy B L B Y L G B L B L G W W W W W W R Br L R Br L L B L B Dg Ch B L Y L B L B Dg Dg B L L B R R B L W BLACK B B B Br Y B B Br Y B L B L G Lg L B ON OFF L Y L G D L G B Y B L B Gy W W W W R R L R G R Br R Y W W R B G W L W R W R B G W L Y G Y Lg L W B R R B B B B R Br L L B Lg L G R R B B L W B R G R L G L G L B Br L Br L 1 ...

Page 309: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 14 Battery 15 Main fuse ...

Page 310: ...CKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 74 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 74 Replace the rectifier regulator 5 Check the entire charging system wiring Refer t...

Page 311: ...CHARGING SYSTEM 8 14 ...

Page 312: ... L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O B...

Page 313: ...ht fuse 13 Taillight fuse 14 Battery 15 Main fuse 29 ECU engine control unit 47 License plate light 51 Tail brake light 54 Dimmer switch 59 Front right turn signal position light 60 Front left turn signal position light 61 Headlight relay 62 Headlight high beam 63 Headlight low beam 70 Meter light 71 High beam indicator light ...

Page 314: ...n headlight ignition taillight and backup Refer to CHECKING THE FUS ES on page 8 65 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 61...

Page 315: ...G SYSTEM 8 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or repair the lighting sys tem wiring Replace the ECU engine control unit or meter assembly ...

Page 316: ...B L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O ...

Page 317: ...ontrol unit 40 Speed sensor 49 Rear left turn signal light 50 Rear right turn signal light 51 Tail brake light 52 Turn signal relay 55 Horn switch 56 Turn signal switch 57 Rear brake light switch 58 Horn 59 Front right turn signal position light 60 Front left turn signal position light 65 Multi function meter 67 Speedometer 68 Fuel meter 72 Right turn signal indicator light 73 Left turn signal ind...

Page 318: ...S ES on page 8 65 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring...

Page 319: ... Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the rear brake light switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the ...

Page 320: ...tem wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 75 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 76 Replace the speed sensor...

Page 321: ...SIGNALING SYSTEM 8 24 ...

Page 322: ...L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O B ...

Page 323: ...switch 11 Ignition fuse 12 Radiator fan fuse 14 Battery 15 Main fuse 29 ECU engine control unit 34 Coolant temperature sensor 45 Radiator fan motor relay 46 Radiator fan motor 65 Multi function meter 66 Coolant temperature meter ...

Page 324: ... the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 76 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 69 Replace the radiator fan motor relay 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATUR...

Page 325: ...COOLING SYSTEM 8 28 ...

Page 326: ... R Y B L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O...

Page 327: ... 25 Fuel injection system relay 28 Sidestand switch 29 ECU engine control unit 30 Ignition coil 31 Spark plug 32 Fuel injector 1 33 Fuel injector 2 34 Coolant temperature sensor 35 Intake air temperature sensor 36 Intake air pressure sensor 37 O2 sensor 38 Throttle position sensor 39 Lean angle sensor 40 Speed sensor 41 Grip warmer relay OPTION 45 Radiator fan motor relay 61 Headlight relay 65 Mul...

Page 328: ...the clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU engine control unit until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning ligh...

Page 329: ...tes an actuator Details on the fail safe actions are given in the table below Self Diagnostic Function table a b c c d a Main switch OFF b Main switch ON c Engine trouble warning light off d Engine trouble warning light on for 1 4 seconds Fault code No Item Symptom Able un able to start Able un able to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position ...

Page 330: ... Able Able 44 Error in writing the amount of CO adjust ment on EEPROM Error is detected while reading or writing on EEPROM CO adjust ment value Able Able 46 Vehicle system power supply Monitoring voltage Power supply to the fuel injection system is not normal Able Able 50 ECU engine control unit internal malfunc tion memory check error Faulty ECU engine control unit memory When this malfunction is...

Page 331: ...e 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 oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction...

Page 332: ...tch to 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET buttons TIP To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1...

Page 333: ...tected Stuck throttle position sensor Malfunction in ECU engine control unit 01 19 A break or disconnection of the blue black lead of the ECU engine control unit is detected Open or short circuit in wire harness Malfunction in ECU engine control unit 20 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfuncti...

Page 334: ...o CHARGING SYSTEM on page 8 11 50 Faulty ECU engine control unit memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Malfunction in ECU engine control unit The program and data are not properly written on or read from the internal memo ry Er 1 No signals are received from the ECU engine con trol unit Open or short circuit in communication line Ma...

Page 335: ...ature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the meter display val ue 07 Vehicle speed pulse 0 999 Check that the number in creases when the front wheel is rotated The number is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees Upright 0 4 1 4 V Overtu...

Page 336: ... fault codes To erase the history set the engine stop switch to 70 Control number 00 255 Diag nostic code No Item Meter display Checking method Diag nostic code No Item Actuation Checking method 30 Ignition coil Actuates the ignition coil five times at one second inter vals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 36 Fuel injector 1 Actua...

Page 337: ...he engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel injection system relay five times 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning lig...

Page 338: ...ion sensor coupler Wire harness ECU engine control unit coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU en gine control u...

Page 339: ...or any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Cranking the engine 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU en gine control unit coupler black blue black blue pink white pink white blue blue 3...

Page 340: ...ne and oper ating it at idle 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor coupler Wire harness ECU engine control unit coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction rep...

Page 341: ...eck the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU engine control unit coupler black blue black blue yellow yellow blue blue 4 Throttle position sensor lead wire open circuit output voltage check...

Page 342: ...mptom A break or disconnection of the blue black lead of the ECU engine control unit is detected Diagnostic code No 20 Sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connection Wire harness ECU engine control unit coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfun...

Page 343: ...or coupler Wire harness ECU engine control unit coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU en gine control unit coupler ...

Page 344: ...ure sensor cou pler Wire harness ECU engine control unit coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler black bl...

Page 345: ...rely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU engine control unit cou pler black blue black blue gray green gray green red blue red blue black black 4 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 3 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom Latch up detected No norm...

Page 346: ... an open or short circuit Between ignition coil connector and ECU engine control unit coupler orange orange Between ignition coil connector and right handlebar switch cou pler red black red black 3 Defective ignition coil Execute the diagnostic mode Code No 30 Replace if defective Refer to CHECKING THE IG NITION COIL on page 8 71 Fault code No 37 Symptom Engine speed is high when the engine is idl...

Page 347: ...e coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Reinstated im mediately when it becomes nor mal 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU engine con trol unit coupler black blue black blue yel...

Page 348: ...l injection sys tem relay coupler and ECU en gine control unit coupler red blue red blue Between the fuse box coupler and fuel injection system relay coupler red blue red blue Between the fuse box coupler and battery terminal red red 4 Malfunction or open circuit in fuel in jection system relay Execute the diagnostic mode Code No 50 Replace if defective If there is no malfunction with the fuel inj...

Page 349: ...ge 8 66 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery terminal and main switch coupler red red Between main switch coupler and fuse box coupler brown blue brown blue Between fuse box coupler and ECU engine control unit cou pler red white ...

Page 350: ...B L B Dg BLACK Dg L B BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R W L W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O ...

Page 351: ...FUEL PUMP SYSTEM 8 54 4 Main switch 7 Fuel injection system fuse 11 Ignition fuse 14 Battery 15 Main fuse 20 Engine stop switch 25 Fuel injection system relay 26 Fuel pump 29 ECU engine control unit ...

Page 352: ... replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 61 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 8 69 Replace the fuel injection system relay 6 Check the fuel pum...

Page 353: ...FUEL PUMP SYSTEM 8 56 ...

Page 354: ...ELECTRICAL COMPONENTS 8 57 EAS27971 ELECTRICAL COMPONENTS 1 10 2 3 4 5 6 7 8 11 12 14 15 16 17 18 19 13 9 ...

Page 355: ...fuse 5 Starter relay 6 Diode 2 7 Diode 1 8 Rectifier regulator 9 Ignition coil 10 Speed sensor 11 Turn signal relay 12 Horn 13 ECU electronic control unit 14 Lean angle sensor 15 Starting circuit cut off relay 16 Headlight relay 17 Fuse box 18 Radiator fan motor relay 19 Fuel injection system relay ...

Page 356: ...ELECTRICAL COMPONENTS 8 59 2 1 3 4 5 6 10 8 9 11 7 ...

Page 357: ...Main switch 2 Intake air temperature sensor 3 Throttle position sensor 4 Intake air pressure sensor 5 Coolant temperature sensor 6 Fuel pump 7 O2 sensor 8 Crankshaft position sensor 9 Stator coil 10 Sidestand switch 11 Radiator fan ...

Page 358: ... 61 EAS27980 CHECKING THE SWITCHES Br L Y Y Br W Ch Dg Br B Y L B BLACK L Y B NR N NL Br W Ch Dg B Y B W L B Y Br G Y R W R B B L W R Br L ON OFF R Br L L G L B R L G B B BLUE L B L G Br B G Y R B R W L W 10 1 2 3 5 6 7 4 8 9 ...

Page 359: ...MPONENTS 8 62 1 Dimmer switch 2 Horn switch 3 Turn signal switch 4 Rear brake light switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch 9 Sidestand switch 10 Storage box light switch ...

Page 360: ...ge 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 position ...

Page 361: ...n of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA4B51012 Since the headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA4B51010 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching ...

Page 362: ...the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EW...

Page 363: ...ing amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated L...

Page 364: ...t tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery s...

Page 365: ...rior to charging TIP Voltage should be measured 30 minutes after the engine is turned off b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve R...

Page 366: ...elay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe G W G Y L Y Lg 1 2 3 4 R B B L W R R 1 2 4 3 4 Negative tester probe Result Continuity between 3 and 4 1 Positive batte...

Page 367: ...Connect the pocket tester DC 20 V to the turn signal relay terminal as shown 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 Turn signal relay input voltage DC 12 V L R L R...

Page 368: ...p resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28080 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω...

Page 369: ... from the spark plug b Connect the ignition checker 1 as shown c Turn the main switch to ON and set the en gine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness Pocket test...

Page 370: ...ATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 9 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn...

Page 371: ... the engine tachometer to the spark plug lead of cylinder 1 b Connect the pocket tester AC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approximate ly 5000 r min d Measure the rectifier regulator output volt age Stator coil resistance 0 225 0 275 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative ...

Page 372: ...SSIS on page 4 1 2 Remove Fuel pump from the fuel tank Refer to FUEL TANK on page 7 1 3 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 1 to the fuel pump terminals as shown b Move the fuel sender float to empty fuel tank position 3 and full fuel tank position 4 level position Coil resistance 1 06 1 11 Ω at 20 C 68 F Pocket tester 9089...

Page 373: ... rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 7 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature s...

Page 374: ...e pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor TIP When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 8 EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage...

Page 375: ...hocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the in take air temperature sensor terminal as shown b Measure the intake air temperature sensor resistance Positive tester probe blue 1 Negative tester probe pink white 2 Intake air temperature sensor re sistance 2 21 2...

Page 376: ...ELECTRICAL COMPONENTS 8 79 ...

Page 377: ... FAILURE HARD STARTING 9 1 INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 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 378: ...Faulty fuel injection system relay Damaged vacuum hose Improperly routed hose 3 Throttle body 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 damag...

Page 379: ...ear Clutch slips 1 Clutch Improperly assembled clutch Fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation Worn pin groove Worn pin 3 Clutch ...

Page 380: ...il seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handleba...

Page 381: ...ong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal...

Page 382: ... motor 47 License plate light 48 Taillight assembly 49 Rear left turn signal light 50 Rear right turn signal light 51 Tail brake light 52 Turn signal relay 53 Left handlebar switch 54 Dimmer switch 55 Horn switch 56 Turn signal switch 57 Rear brake light switch 58 Horn 59 Front right turn signal position light 60 Front left turn signal position light 61 Headlight relay 62 Headlight high beam 63 He...

Page 383: ......

Page 384: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 385: ...BLACK L B Dg BLACK Dg L B BLACK L W Br G Y R B R W G W Br B G Y R B R WL W L B L G Lg L B B B BLUE B BLUE Lg Y Br W Ch Dg Br B Y L B BLACK BLACK L Y B B Ch Dg Br W Y G Y L B Br Br NR N NL OFF ON ON OFF B Y B L Y R B R L L Y L W R W L B W B W O G R Br W P W Gy G Y B B L Y L Y G W Y Y R Y L Gy G R L L Y B L B L Y G B L P W L L B L W L R B B L L W B B G B G B R L R B R B O B O B R L L B Br R L Y Br B...

Page 386: ...NESS BLACK BLACK BLACK BLACK RED RED BLUE BLUE BLUE BLUE BLACK BLACK GREEN GREEN BLACK BLACK BLACK B B GREEN GREEN DARK BLUE BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLACK BLACK C C C B B A A D B A A D B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 17 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 59 61 63 62 64 65...

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