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Yamaha 2009 YZF-R1 (Y) Service Manual Download Page 318

CRANKCASE

5-73

EAS25550

DISASSEMBLING THE CRANKCASE

1. Place the engine upside down.
2. Remove:

• Crankcase bolts

TIP

• Loosen each bolt 1/4 of a turn at a time, in 

stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them.

• Loosen the bolts in increasing numerical 

order (refer to the numbers in the illustration).

• The numbers embossed on the crankcase 

indicate the crankcase tightening sequence.

3. Remove:

• Lower crankcase

ECA13900

Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the 
crankcase mating surfaces. Work slowly 
and carefully and make sure the crankcase 
halves separate evenly.

4. Remove:

• Dowel pins

EAS25580

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a 

mild solvent.

2. Thoroughly clean all the gasket surfaces 

and crankcase mating surfaces.

3. Check:

• Crankcase

Cracks/damage 

→

 Replace.

• Oil delivery passages

Obstruction 

→

 Blow out with compressed 

air.

EAS25650

ASSEMBLING THE CRANKCASE

1. Lubricate:

• Crankshaft journal bearings

(with the recommended lubricant)

2. Apply:

• Sealant

(onto the crankcase mating surfaces)

TIP

Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm 
(0.08–0.12 in) of the crankshaft journal bear-
ings.

3. Install:

• Dowel pins

4. Set the shift drum assembly and transmis-

sion gears in the neutral position.

5. Install:

• Lower crankcase “1”

(onto the upper crankcase “2”)

ECA13980

Before tightening the crankcase bolts, 
make sure the transmission gears shift cor-
rectly when the shift drum assembly is 
turned by hand.

Recommended lubricant

Engine oil

Yamaha bond No.1215

(Three Bond No.1215®)
90890-85505

Summary of Contents for 2009 YZF-R1 (Y)

Page 1: ...SERVICE MANUAL YZF R1 Y 2009 14B 28197 E0 ...

Page 2: ...F R1 Y SERVICE MANUAL 2008 by Yamaha Motor Co Ltd First edition November 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ... significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert sym...

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

Page 5: ...N SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOC TITE Engine oil Replace the part with a new one ...

Page 6: ......

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

Page 8: ......

Page 9: ...led Throttle YCC I Yamaha Chip Controlled Intake 1 4 INSTRUMENT FUNCTIONS 1 8 IMPORTANT INFORMATION 1 16 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 16 REPLACEMENT PARTS 1 16 GASKETS OIL SEALS AND O RINGS 1 16 LOCK WASHERS PLATES AND COTTER PINS 1 16 BEARINGS AND OIL SEALS 1 17 CIRCLIPS 1 17 CHECKING THE CONNECTIONS 1 18 HANDLING THE ELECTRONIC PARTS 1 19 SPECIAL TOOLS 1 20 ...

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

Page 11: ...st gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel inj...

Page 12: ...tion sensor coolant temperature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor air temperature sensor speed sensor and O2 sensor enable the ECU to deter mine the injection duration The injection timing is determined through the signals from the crank shaft position sensor and cylinder identification sensor A...

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

Page 14: ...YCC I offers higher levels of power across the RPM range Electronically controlled intake length The YCC I system consists of four lightweight plastic resin funnels and each of these is divided into an upper and lower portion Depending upon operating conditions the funnels can be joined to form a single long funnel or split to create a short funnel This change is performed instanta neously by an e...

Page 15: ...or driver 8 Throttle servo motor driver operation sens ing shut off circuit 9 Throttle servo motor driver operation sens ing feedback emergency stop 10 Emergency stop 11 Engine revolution pulse signal 12 Sensor input 13 Neutral switch 14 Crankshaft position sensor 15 Speed sensor 16 Coolant temperature sensor 17 Atmospheric pressure sensor 18 Intake funnel servo motor driver 19 Intake funnel servo...

Page 16: ...tmospheric pressure sensor 9 Accelerator position two signals 10 Throttle position two signals 11 Engine revolution 12 Vehicle speed 13 Coolant temperature 14 Neutral In gear 15 Atmospheric pressure 16 Throttle servo motor 17 ECU engine control unit 18 Base map 19 Idle speed control 20 Calculated throttle valve opening angle 21 Base map 22 Air funnel position Calculation value 23 Intake funnel ser...

Page 17: ...hift timing indicator light and throttle opening position display control mode TIP Be sure to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the speedometer and odometer tripmeter fuel consumption displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine sp...

Page 18: ...CT button to stop the stopwatch and display the total elapsed time Split time history The split time history displays up to 20 stored split times The split time history can be dis played either in reverse chronological order or by speed 1 Push the SELECT button for at least one second to select the reverse chronological order mode L20 displays on the stop watch Push the SELECT button again to sele...

Page 19: ...ollowing order TRIP F km L or L 100 km AV_ _ _ km L or AV_ _ _ L 100 km ODO TRIP 1 TRIP 2 TRIP F For the UK only TRIP F km L L 100 km or MPG AV_ _ _ km L AV_ _ _ L 100 km or AV_ _ _ MPG ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter select it by pushing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it resets itself a...

Page 20: ...e displays is shown To reset the average fuel consumption display select it by pushing the SELECT button and then push the RESET button for at least one second TIP After resetting an average fuel consumption display _ _ _ is shown for that display until the vehicle has traveled 1 km 0 6 mi Transmission gear display This display shows the selected gear The neutral position is indicated by and by th...

Page 21: ...temperature of the air drawn into the air fil ter case Turn the key to ON and push the RESET button to switch the coolant tempera ture display to the air intake temperature dis play Push the RESET button again to return to the coolant temperature display TIP Even if the air intake temperature is set to be displayed the coolant temperature warning light comes on if the engine overheats When the key...

Page 22: ...r code the vehicle should be checked as soon as pos sible in order to avoid engine damage Display brightness shift timing indicator light and throttle opening position display control mode This mode allows you to make changes to six settings by performing the following steps 1 Turn the key to OFF 2 Push and hold the SELECT button 3 Turn the key to ON and then release the SELECT button after five s...

Page 23: ...in the indi cator light can be set in increments of 200 r min 1 Push the RESET button to select the desired engine speed for activating the indicator light 2 Push the SELECT button to confirm the selected engine speed The control mode changes to the shift timing indicator light deactivation function To set the shift timing indicator light deactiva tion function TIP The shift timing indicator light...

Page 24: ...nge Mode A Mode A offers a sportier engine response in the low to mid speed range compared to mode STD Mode B Mode B offers response that is somewhat less sharp compared to mode STD for riding situations that require especially sensitive throttle operation Drive mode switch MODE WARNING EWA14B1025 Do not change the D mode while the vehi cle is moving Using this switch changes the drive mode to STD...

Page 25: ... 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 26: ...ed grease Oil bearings liberally when installing if appro priate ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposi...

Page 27: ...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 28: ...ectricity and it s voltage is very high and electronic parts is very sensitive It has possibility that inside small parts of elec tronic parts is destroyed by static electricity Do not touch and do not make it dirty When you disconnect electronic parts from wire harness always turn off main switch If you disconnect above condition it may gives damages to electronic parts ...

Page 29: ...depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 76 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6...

Page 30: ...per rod holder 90890 01506 YM 01506 4 63 4 65 Oil filter wrench 90890 01426 YU 38411 3 29 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 62 4 67 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 66 4 67 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 31: ...ng compressor 90890 01441 YM 01441 4 62 4 67 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 65 4 66 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 10 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Tool name Tool No Illustration Reference pages YM A8703 YU 44456 ...

Page 32: ...pressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 30 5 36 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 14 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 14 Universal clutch holder 90890 04086 YM 91042 5 63 5 67 Tool name Tool No Illustration Reference pages ...

Page 33: ...0 mm YM 04098 5 32 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 32 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 32 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 32 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 132 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 10 Tool name ...

Page 34: ...ressure adapter H 90890 03139 3 30 Pressure gauge 90890 03153 YU 03153 3 30 7 18 Fuel pressure adapter 90890 03176 YM 03176 7 18 Fuel injector pressure adapter 90890 03210 YU 03210 7 18 Camshaft wrench 90890 04143 YM 04143 5 17 5 21 Ring nut wrench 90890 01507 YM 01507 4 80 4 82 Tool name Tool No Illustration Reference pages ...

Page 35: ...38 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 38 5 41 5 42 5 44 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 18 8 123 8 124 8 125 8 129 8 130 8 131 8 132 8 133 8 135 8 136 8 137 8 138 8 139 8 140 8 141 8 142 8 143 8 144 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 48 8 134 8 140 8 142 Tool name Tool No Illustration Reference pag...

Page 36: ... 03208 8 137 8 141 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 133 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 140 8 142 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 24 5 39 5 45 5 73 Tool name Tool No Illustration Reference pages ...

Page 37: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 26 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 45 CABLE ROUTING 2 49 ...

Page 38: ...PRT SVN SWE ZAF 14B2 BEL FRA 14B3 AUS Dimensions Overall length 2070 mm 81 5 in Overall width 715 mm 28 1 in Overall height 1130 mm 44 5 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel 206 kg 454 lb Maximum load 189 kg 417 lb ...

Page 39: ...m Wet sump Engine oil quantity Total amount 4 58 L 4 84 US qt 4 03 Imp qt Without oil filter cartridge replacement 3 73 L 3 94 US qt 3 28 Imp qt With oil filter cartridge replacement 3 93 L 4 15 US qt 3 46 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump h...

Page 40: ...n Cylinder head Volume 14 43 15 23 cm 0 88 0 93 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 25 500 25 521 mm 1 0039 1 0048 in Camshaft journal diameter 25 459 25 472 mm 1 0023 1 0028 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Intake A 37 350 37 450 mm 1 4705 1 4744 in Limit 37...

Page 41: ... mm 0 0433 0 0512 in Limit 1 80 mm 0 07 in Valve margin thickness D intake 1 35 1 75 mm 0 0532 0 0689 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 960 mm 0 1953 in Valve stem diameter exhaust 4 460 4 475 mm 0 1756 0 1762 in Limit 4 425 mm 0 1742 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0 1973...

Page 42: ... 72 kgf 41 59 47 88 lbf Spring tilt limit intake 2 5 1 7 mm 0 067 in Spring tilt limit exhaust 2 5 1 7 mm 0 067 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 150 mm 0 0059 in Pist...

Page 43: ... mm 0 0039 0 0157 in Connecting rod Crankshaft pin to big end bearing clearance 0 034 0 058 mm 0 0013 0 0023 in Limit 0 09 mm 0 0035 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Width A 59 40 60 10 mm 2 339 2 366 in Width B 301 80 303 00 mm 11 88 11 93 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 Journal oil clearance 0 004 0 039 ...

Page 44: ...ration Left foot operation Gear ratio 1st 38 15 2 533 2nd 33 16 2 063 3rd 37 21 1 762 4th 35 23 1 522 5th 30 22 1 364 6th 33 26 1 269 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0 100 mm 0 0039 in Shift fork L thickness 5 795 5 868 mm 0 2281 0 2310 in Shift for...

Page 45: ...e sensor output voltage 3 57 3 71 V at 101 32 kPa Intake air pressure sensor output voltage 3 57 3 71 V at 101 32 kPa Intake air temperature sensor resistance 5 4 6 6 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F Air induction system Reed valve bending limit 0 4 mm 0 016 in Solenoid resistance 18 22 Ω at 20 C 68 F Idling condition Engine idling speed 1150 1250 r min CO at exhaust pipe 2 6 3 6 Intake vacu...

Page 46: ...t front 1 0 mm 0 04 in 14B3 1 6 mm 0 06 in 14B1 14B2 Rear tire Type Tubeless Size 190 55 ZR17M C 75W Manufacturer model MICHELIN Pilot POWER 14B1 14B2 DUNLOP D210 14B1 14B3 Wear limit rear 1 0 mm 0 04 in 14B3 1 6 mm 0 06 in 14B1 14B2 Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42 psi 2 90 bar Loading...

Page 47: ...r cylinder inside diameter 38 18 mm 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 27 0 Center to lock angle right 27 0 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 271 5 mm 10 69 in Limit 266 1 mm 10 48 in Collar length 118 4 mm 4 66 in In...

Page 48: ...ximum 0 Rebound damping adjusting positions Minimum 20 Standard 15 Maximum 3 Compression damping setting for fast compression damping Minimum 4 Standard 3 Maximum 0 Compression damping setting for slow compression damping Minimum 20 Standard 9 Maximum 1 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive chain Type manufacturer 50VAZ ...

Page 49: ...rcuit Rectifier regulator output voltage 14 2 14 8 V Rectifier regulator input voltage above 14 V at 5000 r min Rectifier capacity 50 0 A Lean angle sensor Lean angle sensor output voltage Less than 45 0 4 1 4 V More than 45 3 7 4 4 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 31 Manufacturer GS YUASA Ten hour rate amperage 0 90 A Headlight Bulb type Halogen bulb Bulb vol...

Page 50: ...24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pcs Maximum amperage 3 0 A Coil resistance 1 07 1 11 Ω at 20 C 68 F Turn signal hazard relay Relay type Full transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Ω Minimum level positi...

Page 51: ...ignaling system fuse 7 5 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Turn signal light fuse 7 5 A Fuel injection system fuse 15 0 A Steering damper fuse 7 5 A Backup fuse 7 5 A ETV Electronic Throttle Valve fuse 7 5 A Spare fuse 20 0 A Spare fuse 15 0 A 2 Spare fuse 7 5 A ...

Page 52: ...l To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 6...

Page 53: ... kgf 7 2 ft lbf Water pump inlet pipe bolt water pump side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water hose clamp 6 2 Nm 0 2 m kgf 1 4 ft lbf Oil water pump driven sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil water pump assembly bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Thermostat housing cover nut M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Therm...

Page 54: ...m kgf 14 ft lbf Exhaust pipe and exhaust cham ber clamp bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Muffler and frame bolt M8 2 23 Nm 2 3 m kgf 17 ft lbf Muffler cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Exhaust chamber protector bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Muffler pipe cover bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Crankcase stud bolt M10 10 8 Nm 0 8 m kgf 5 8 ft lbf Crankcase bolt main journal M9 1...

Page 55: ...6 4 7 Nm 0 7 m kgf 5 1 ft lbf Right side cowling inner panel bracket bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Idler gear bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch holder bolt M6 3 14 Nm 1 4 m kgf 10 ft lbf Clutch boss nut M20 1 115 Nm 11 5 m kgf 85 ft lbf Stake Clutch spring bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Drive sprocket nut M22 1 85 Nm 8 5 m kgf 61 ft lbf Stake Bearing housing bolt M6 ...

Page 56: ... 3 Retighten the bolt further to reach the specified angle of 145 155 TIP Crankcase bolt main journal 1 Lubricate the bolts thread mating surfaces and washers with engine oil 2 First tighten the bolts to approximately 30 Nm 3 0 m kgf 22 ft lbf with a torque wrench 3 Loosen all the bolts one by one following the tightening order and then tighten them to 18 Nm 1 8 m kgf 13 ft lbf again 4 Retighten t...

Page 57: ...ft lbf Rear shock absorber assembly lower nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly and bracket nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly bracket and frame nut M16 1 92 Nm 9 2 m kgf 66 ft lbf Drive chain guide bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Locknut drive chain adjusting nut M8 2 16 Nm 1 6 m kgf...

Page 58: ... kgf 5 1 ft lbf Rear fuel tank bracket and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank and rear fuel tank bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank upper cover and frame bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank upper cover and fuel tank bolt rear M5 2 4 Nm 0 4 m kgf 2 9 ft lbf Fuel tank upper cover and fuel tank bolt side M5 2 0 4 Nm 0 04 m kgf 0 29 ft lbf Fuel tank s...

Page 59: ...hem by adding the external force by hand or with a plastic hammer etc If the end face of the axle is not parallel to the end face of the fork align them so that one point of the axle circumference is positioned on the end face of the fork Front wheel axle pinch bolt M8 4 21 Nm 2 1 m kgf 15 ft lbf See TIP Rider footrest bolt M8 4 28 Nm 2 8 m kgf 20 ft lbf Passenger footrest bolt M8 4 28 Nm 2 8 m kg...

Page 60: ...n be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order from the pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kgf 15 ft lbf without performing temporary tightening ...

Page 61: ...d washer Crankshaft sprocket bolt thread Balancer gear press fitting surface O rings coolant pipe Oil pump rotors inner and outer Shell Alvania EP Grease Oil cooler bolt thread and washer O ring oil nozzle O ring main gallery plug Idler gear and idler gear shaft Starter clutch assembly Starter clutch gear thrust surface Primary driven gear Clutch boss nut thread and bearing surface Pull rod Oil wa...

Page 62: ...UBRICATION POINTS AND LUBRICANT TYPES 2 25 Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Crankcase cover lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant ...

Page 63: ... and rear shock absorber spacer Swingarm pivot shaft Swingarm pivot shaft bearings Swingarm dust cover lips Relay arm connecting arm and rear shock absorber oil seal lips Seat lock lever pivoting point Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Sidestand bracket and sidestand bolt Shift shaft joint ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 65: ...Oil pump 3 Relief valve 4 Oil cooler 5 Sub gallery 6 Oil filter cartridge 7 Main gallery 8 Mission shower 9 Drive axle 10 Main axle 11 Shift fork upper 12 Crankshaft 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil filter cartridge 5 Oil level switch ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 69: ...TION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Crankshaft 5 Balancer shaft 6 Oil cooler 7 Relief valve 8 Oil pipe 9 Oil strainer 10 Oil water pump assembly ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil level switch 3 Oil strainer 4 Oil pipe 5 Relief valve 6 Oil cooler ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil water pump assembly ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Oil delivery pipe 2 3 Drive axle ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Shift fork guide bar 2 Shift fork C 3 Shift drum assembly 4 Shift fork R 5 Drive axle 6 Shift fork L ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil nozzle 5 Crankshaft ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Balancer shaft 2 Crankshaft ...

Page 82: ...COOLING SYSTEM DIAGRAMS 2 45 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 83: ...COOLING SYSTEM DIAGRAMS 2 46 1 Oil water pump assembly 2 Radiator 3 Radiator fan 4 Thermostat 5 Oil cooler ...

Page 84: ...COOLING SYSTEM DIAGRAMS 2 47 ...

Page 85: ...COOLING SYSTEM DIAGRAMS 2 48 1 Radiator cap 2 Radiator 3 Radiator fan 4 Oil cooler ...

Page 86: ...CABLE ROUTING 2 49 EAS20430 CABLE ROUTING ...

Page 87: ...out The ground lead terminal can be in any side E Route the auxiliary light lead under the front intake air duct and connect F To the main harness G To the turn signal H Cut off the excess end of the clamp I When clamping the headlight sub wire har ness it should not be sagged Face the end of the clamp to front J Route the headlight lead toward the front of the meter bracket and connect K To the m...

Page 88: ...CABLE ROUTING 2 51 ...

Page 89: ...ront brake hose The throttle cable decelerator cable should be on the bottom and the throttle cable accelerator cable should be above Fit the clamp toward outside rather than inside F 30 60 mm 1 18 2 36 in G Route the front brake light switch lead under the brake hose H Route the right handlebar switch lead above the metal fitting on the brake hose I Route the throttle cable above the under bracke...

Page 90: ...CABLE ROUTING 2 53 ...

Page 91: ...lit D Clamp the clutch cable and oil cooler outlet hose at the protector rivet ring of the clutch cable E Clamp the right radiator fan motor lead right handlebar switch lead main harness and AC magneto lead under the rectifier regulator bracket rib and face the end of the clamp down F Clamp the right radiator fan motor lead right handlebar switch lead and AC mag neto lead under the rectifier regul...

Page 92: ...CABLE ROUTING 2 55 ...

Page 93: ...ition coil lead 2 Crankshaft position sensor lead 3 Rear brake light switch lead 4 O2 sensor lead A Route the rear brake light switch lead out side of the O2 sensor lead and push it to the occluding surface of the clutch cover ...

Page 94: ...CABLE ROUTING 2 57 ...

Page 95: ... the rear brake caliper bracket and torque receptor groove of the swing arm G Make sure to pass the brake hose through the brake hose holder H Face the clamp in the direction shown in the illustration I Make sure to bend the cotter pin It can be bent in the same direction J Install the end of the exhaust chamber cover within the area shown in the illustra tion K Projection of the right footrest as...

Page 96: ...CABLE ROUTING 2 59 ...

Page 97: ...perature sensor head light I Align the main switch lead white left han dlebar switch lead gray and steering damper lead white to the tapes and clamp them inside of the front fork J Face the end of the clamp to bottom of the vehicle and insert it into the cable guide K Face the end of the clamp to front and inside of the vehicle L Align the main switch lead white to the tape and clamp it inside of ...

Page 98: ...CABLE ROUTING 2 61 ...

Page 99: ... F 30 50 mm 1 18 1 97 in G Route the fuel tank breather hose fuel tank overflow hose and coolant reservoir breather hose inner side of the water pump bypass hose then through the binding clamp on the sidestand switch and to the outside of the under cover End of the hoses can face in any direction H To the oil level switch I Route the AC magneto lead through inner side of the coolant reservoir tank...

Page 100: ...CABLE ROUTING 2 63 ...

Page 101: ... lead below the fuel tank breather hose and fuel tank overflow hose back of the fuel hose and above the ground lead and battery negative lead J Install with the ground lead at the bottom and the battery negative lead on the top Install the rivet of the each lead facing up Angle of installing each lead is shown in the illustration K Route the fuel pump lead through front of the fuel tank breather h...

Page 102: ...CABLE ROUTING 2 65 ...

Page 103: ...AE Install the water pump bypass hose with its clamp opening facing right of the vehicle AF Clamp the secondary injector sub wire har ness and throttle sub wire harness at the protector Face the end of the clamp down ward ...

Page 104: ...CABLE ROUTING 2 67 ...

Page 105: ...e left of the battery box 2 boss E After passing the tail brake light lead license plate light lead right turn signal light lead and left turn signal light lead through the guide of the battery box 2 route them between the ribs F When installing the seal align it to the push pin trace mark of the rear frame both left right G Align the positioning tape of the battery negative lead to the clamp H Fa...

Page 106: ...CABLE ROUTING 2 69 ...

Page 107: ...breather hose with its white paint facing front of the vehicle H Install the fuel tank overflow hose with its yellow paint facing front of the vehicle I Install the fuel tank overflow hose and fuel tank breather hose with the clamp opening facing down J Fuel pump side K Insert the connector until the click sound is heard and check that the connector does not come off Make sure that no foreign matt...

Page 108: ...CABLE ROUTING 2 71 ...

Page 109: ...16 Primary injector 2 coupler 17 Primary injector 3 coupler 18 Primary injector 4 coupler 19 Cap A Checker color orange B Checker color black C Rotate the clip to the right of the vehicle D Adjust top edge of the clip to top edge of the paint E Make sure the intake air pressure sensor is touching against the stopper and install it horizontally F After installing the intake air pressure sen sor do ...

Page 110: ...CABLE ROUTING 2 73 ...

Page 111: ...tic locking tie at the branch root of the sub wire harness Position the plastic locking tie as shown in the illustra tion F Position the sub wire harness under the bearing surface of the bolt so that it is not pinched G When installing the air filter case the sub wire harness should not be pinched H Make sure the grommet is not pinched I When installing the cap case assembly the sub wire harness s...

Page 112: ...CABLE ROUTING 2 75 ...

Page 113: ...HE REAR DISC BRAKE 3 16 CHECKING THE REAR BRAKE PADS 3 17 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 17 CHECKING THE FRONT BRAKE HOSES 3 18 CHECKING THE REAR BRAKE HOSE 3 19 CHECKING THE WHEELS 3 19 CHECKING THE TIRES 3 19 CHECKING THE WHEEL BEARINGS 3 21 CHECKING THE SWINGARM OPERATION 3 21 ADJUSTING THE DRIVE CHAIN SLACK 3 21 LUBRICATING THE DRIVE CHAIN 3 22 CHECKING AND ADJUSTING THE STEERING HEAD 3...

Page 114: ... LIGHT SWITCH 3 33 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 34 LUBRICATING THE REAR SUSPENSION 3 34 CHECKING AND CHARGING THE BATTERY 3 34 CHECKING THE FUSES 3 34 REPLACING THE HEADLIGHT BULBS 3 34 ADJUSTING THE HEADLIGHT BEAMS 3 35 ...

Page 115: ......

Page 116: ...kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20...

Page 117: ...sed grease Every 50000 km 30000 mi 10 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 800 km 500 mi and after washing the motorcycle or riding in the rain 11 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 12 Steering damper Check ...

Page 118: ...ke hoses every four years and if cracked or damaged 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter cartridge Replace 25 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Throttle grip hous ing and cable Check operation and free play ...

Page 119: ...el tank breather hose is routed correctly 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1114 CHECKING THE FUEL LINE Secondary injector 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Fuel tank Refer to FUEL TANK on page 7 1 3 Check Fuel hose 1 Cracks damage Replace Loose connection Connect properly TIP Before re...

Page 120: ...he spark plug and gasket surface 11 Install Ignition coil 12 Install Air filter case Refer to AIR FILTER CASE on page 7 5 13 Install Fuel tank Refer to FUEL TANK on page 7 1 14 Install Lower cowlings Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold e...

Page 121: ...valve clearance in the following sequence a Turn the crankshaft clockwise and align the pickup rotor K mark a and crankcase occluding surface b At this time make sure the intake cam shaft sprocket punch mark c and cylinder head occluding surface d and exhaust camshaft sprocket punch mark e and cyl inder head occluding surface f are aligned If not repeat until they are aligned b Turn the crankshaft...

Page 122: ...kup rotor T mark a upward g Measure the valve clearance 2 with a thickness gauge h Turn the crankshaft 90 degrees in clock wise and position the pickup rotor T mark a opposite side of TDC i Measure the valve clearance 4 with a thickness gauge 5 Remove Camshafts Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 b 270 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 b 180 Thickness gaug...

Page 123: ... 0 0043 0 0079 in Measured valve clearance 0 23 mm 0 0091 in 0 23 mm 0 0091 in 0 20 mm 0 0079 in 0 03 mm 0 0012 in c Check the thickness of the current valve pad TIP The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Example If the valve pad is marked 155 the pad thickness is 1 55 mm 0 0610 in d Calculate the sum of the values obtaine...

Page 124: ...the valve clearance is still out of specifi cation repeat all of the valve clearance adjustment steps until the specified clear ance is obtained 7 Install All removed parts TIP For installation reverse the removal proce dure EAS20571 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body ...

Page 125: ... out ECA14B1039 Do not turns the bypass air screw at the throttle body which is the base for synchro nizing otherwise the engine may run roughly at idle and the throttle bodies may not operate properly TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn in the screw fully and be sure to sy...

Page 126: ...se breather hose 1 Cracks damage Replace Loose connection Connect properly ECA13450 Make sure the crankcase breather hose is routed correctly 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets 1 Remove Rider seat Refer to GENERAL CHA...

Page 127: ...N and continue to press the buttons for 8 seconds or more TIP dIAG appears on the odometer tripmeter and fuel reserve trip LCD 3 Press the SELECT button to select the CO adjustment mode CO or the diagnos tic mode dIAG 4 After selecting CO simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf Exhaust pipe and exha...

Page 128: ...s the SELECT button 8 Release the button to execute the selec tion 9 Simultaneously press the SELECT and RESET buttons to return to the cylinder selection step 5 10 Turn the main switch to OFF to cancel the CO adjustment mode EAS14B1099 CHECKING THE AIR INDUCTION SYSTEM Refer to CHECKING THE AIR INDUCTION SYSTEM on page 7 25 EAS20961 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Refer to GE...

Page 129: ...ider seat Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust 2 Adjust Clutch cable free play Handlebar side a Turn the adjusting bolt 1 in direction a or b until the specified clutch lever free play is obtained TIP If the specified clutch cable free play cannot be obtained on the handlebar side of the cabl...

Page 130: ... level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid ...

Page 131: ...sibly an accident Therefore check and if necessary bleed the brake system ECA13490 After adjusting the brake lever position make sure there is no brake drag 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 indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on p...

Page 132: ...ds as a set Refer to REAR BRAKE on page 4 43 EAS21360 BLEEDING THE HYDRAULIC BRAKE SYS TEM WARNING EWA13100 Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow When bleeding the hyd...

Page 133: ...rake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and ...

Page 134: ...A13260 Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or replaced always balance the wheel EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature ...

Page 135: ...mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42 psi 2 90 bar Loading condition 90 189 kg 198 417 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42...

Page 136: ... can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Move the rear wheel several times and find the tightest position of d...

Page 137: ...ins Do not use any other lubricants on the drive chain since they may contain sol vents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 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 a suitable stand so that the front wheel is elevated 2 Check Steering head ...

Page 138: ...on page 4 73 EAS14B1093 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 20 EAS21700 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the levers EAS14B1100 LUBRICATING THE CLUTCH LEVER Lubricate the pivoting point and metal to metal moving parts of the levers EAS21...

Page 139: ... CHECKING THE SIDESTAND SWITCH Refer to ELECTRICAL COMPONENTS on page 8 117 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push ...

Page 140: ...er go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping right side a Turn the adjusting screw 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 0 Standard 2 Maximum 5 Direction a Rebound damping is increased suspension is harder Directi...

Page 141: ...ing pre load adjusting bolt b Turn the spring preload adjusting bolt 1 in direction a or b c Align the desired position on the mark 2 with the match mark 3 Rebound damping ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Co...

Page 142: ... a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 20 click s out Standard 15 click s out Maximum 3 click s out With the adjusting screw fully turned in Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Minimum...

Page 143: ...mark Add the recommended engine oil to the proper level ECA13360 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERV ING II Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for se...

Page 144: ...artridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of lithium soap based grease ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter car tridge c Tighten the new oil filter cartridge to speci fication with an oil ...

Page 145: ...ine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are extremely hot 4 Install Oil pressure gauge 1 Oil pressure adapter H 2 5 Measure Engine oil pressure at the following conditions Out of specification Check...

Page 146: ...warm it up for several minutes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4 1 2 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Oil cooler 6 Water jacket j...

Page 147: ...nterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 5 Remove Coolant drain bolt engine 1 along with the copper washer 6 Drain Coolant from the engine and radiator 7 Install Coolant drain bolt with the copper washer 8 Install Coolant reservoir 9 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coola...

Page 148: ...page 3 31 TIP Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4 1 EAS14B1098 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer to ELECTRICAL COMPONENTS on page 8 117 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by movement of the brake pedal The rear b...

Page 149: ... c Tighten the locknut 1 WARNING EWA14B1016 After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension EAS21760 CHECKING AND CHARGING THE BATTERY Refe...

Page 150: ...dlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install Headlight bulb holder 6 Connect Headlight coupler 7 Install Headlight bulb cover EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horiz...

Page 151: ...PERIODIC MAINTENANCE 3 36 ...

Page 152: ...PERIODIC MAINTENANCE 3 37 ...

Page 153: ...E AIR DUCT COVERS 4 14 INSTALLING THE AIR INTAKE DUCTS 4 14 INSTALLING THE REAR VIEW MIRRORS 4 14 REMOVING THE WINDSHIELD 4 15 INSTALLING THE WINDSHIELD 4 15 INSTALLING THE MIRROR FITTING PLATES 4 15 REMOVING THE UPPER TAIL COVER 4 15 INSTALLING THE UPPER TAIL COVER 4 16 INSTALLING THE TAIL BRAKE LIGHT 4 16 ADJUSTING THE RIDER FOOTRESTS 4 16 FRONT WHEEL 4 18 REMOVING THE FRONT WHEEL 4 20 CHECKING ...

Page 154: ...INDER 4 52 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 53 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 53 HANDLEBARS 4 55 REMOVING THE HANDLEBAR 4 57 CHECKING THE HANDLEBARS 4 57 INSTALLING THE HANDLEBARS 4 57 FRONT FORK 4 59 REMOVING THE FRONT FORK LEGS 4 62 DISASSEMBLING THE FRONT FORK LEGS 4 62 CHECKING THE FRONT FORK LEGS 4 64 ASSEMBLING THE FRONT FORK LEGS 4 64 INSTALLING THE FRONT FORK LEGS 4...

Page 155: ...NGARM 4 81 INSTALLING THE SWINGARM 4 81 CHAIN DRIVE 4 83 REMOVING THE DRIVE CHAIN 4 84 CHECKING THE DRIVE CHAIN 4 84 CHECKING THE DRIVE SPROCKET 4 85 CHECKING THE REAR WHEEL SPROCKET 4 85 CHECKING THE REAR WHEEL DRIVE HUB 4 85 INSTALLING THE DRIVE CHAIN 4 85 ...

Page 156: ...b Parts to remove Q ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Battery negative lead 1 Disconnect 4 Battery positive lead 1 Disconnect 5 Tool band 1 6 Tool 1 7 Upper tail cover bracket 2 8 Battery cover 1 9 Battery 1 10 Battery seat 1 For installation reverse the removal proce dure ...

Page 157: ...er Job Parts to remove Q ty Remarks 1 Front cowling inner panel 2 2 Side cowling 2 3 Front turn signal light coupler 2 Disconnect 4 Front turn signal light 2 5 Lower cowling 2 6 Side cowling inner panel 2 For installation reverse the removal proce dure ...

Page 158: ...HASSIS on page 4 1 1 ECU coupler 2 Disconnect 2 ECU 1 3 Radiator fan motor relay coupler 1 Disconnect 4 Radiator fan motor relay 1 5 ECU bracket 1 6 Rectifier regulator coupler 1 Disconnect 7 Stator coil lead coupler 1 Disconnect 8 Rectifier regulator bracket 1 9 Rectifier regulator 1 For installation reverse the removal proce dure ...

Page 159: ... CHASSIS on page 4 1 ECU and rectifier regulator Refer to GENERAL CHASSIS on page 4 1 1 Air chamber cover 2 2 Air chamber 2 3 Air chamber bracket 2 4 Air intake air duct cover 2 5 Rear intake air duct upper 2 6 Rear intake air duct lower 2 7 Front intake air duct 2 For installation reverse the removal proce dure ...

Page 160: ... page 4 1 ECU and Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 Air duct Refer to GENERAL CHASSIS on page 4 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Auxiliary light coupler 2 Disconnect 3 Headlight sub wire harness coupler 2 Disconnect 4 Front cowling assembly 1 For installation reverse the removal proce dure ...

Page 161: ... Air duct Refer to GENERAL CHASSIS on page 4 1 Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 1 Rear view mirror 2 2 Meter bracket 1 3 Headlight coupler 1 Disconnect 4 Meter coupler 1 Disconnect 5 Meter assembly 1 6 Ground lead 1 Disconnect 7 Headlight relay coupler 1 Disconnect 8 Headlight relay 1 9 Turn signal relay coupler 1 Disconnect 10 Turn signal relay 1 11 Headlight sub wire h...

Page 162: ...4 7 Removing the meter and headlight Order Job Parts to remove Q ty Remarks 12 Windshield 1 13 Intake air temperature sensor 1 14 Headlight assembly 1 15 Front cowling 1 For installation reverse the removal proce dure ...

Page 163: ...adlight assembly Order Job Parts to remove Q ty Remarks 1 Auxiliary light socket 2 2 Auxiliary light bulb 2 3 Headlight bulb cover 2 4 Headlight bulb 2 5 Headlight harness 1 6 Headlight grille 2 For installation reverse the removal proce dure ...

Page 164: ...2 Refer to ENGINE REMOVAL on page 5 3 3 Passenger seat lock cable 1 4 Passenger seat lock key cylinder 1 5 Lower tail cover bracket 1 6 Passenger seat lock assembly 1 7 Tail brake light lead coupler 1 Disconnect 8 Rear turn signal light lead coupler 2 Disconnect 9 License plate light lead connector 2 Disconnect 10 License plate turn signal light assembly 1 11 Lower tail cover 1 12 Tail brake light...

Page 165: ...sembly Order Job Parts to remove Q ty Remarks 1 License plate turn signal light stay 1 2 License plate turn signal light stay plate 1 3 Cover 1 4 Rear turn signal light 2 5 License plate light 1 6 Rear reflector 1 7 Mudguard 1 For installation reverse the removal proce dure ...

Page 166: ...ith a screwdriver Make sure that the screw is flush with the fastener s head EAS14B1031 REMOVING THE QUICK FASTENER PUSH TYPE TIP To remove the quick fastener push its center with a screwdriver then pull the fastener out EAS14B1032 INSTALLING THE QUICK FASTENER PUSH TYPE TIP To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cov...

Page 167: ...Lock stay 2 Lock spring 3 TIP Align the projection a of the passenger seat lock key cylinder 1 to the grooves b of the lower tail cover and lock stay 2 and install EAS14B1038 REMOVING THE FRONT TURN SIGNAL LIGHTS 1 Remove Stay 1 Front turn signal light 2 TIP Remove the stay 1 first and then remove the front turn signal light 2 from the side cowling EAS14B1039 INSTALLING THE FRONT TURN SIGNAL LIGHT...

Page 168: ... Side cowling inner panel 1 TIP When removing the side cowling inner panel downward pull out the side cowling inner panel hole from the projection a of the air chamber cover 2 EAS14B1043 INSTALLING THE SIDE COWLING INNER PANELS 1 Install Side cowling inner panel 1 TIP Install the grommet 2 to the side cowling inner panel and insert them into the projection a of the air chamber cover 3 EAS14B1044 R...

Page 169: ...AKE AIR DUCT COV ERS 1 Install Intake air duct cover 1 TIP Align the intake air duct cover tabs a and the tab b of the front cowling 2 as shown in the illustration and install EAS14B1048 INSTALLING THE AIR INTAKE DUCTS 1 Install Rear air intake duct 1 to front air intake duct 2 TIP Insert the rear air intake duct tabs a into the front air intake duct grooves b EAS14B1013 INSTALLING THE REAR VIEW M...

Page 170: ...ror fitting plate 1 to meter bracket 2 TIP Face the mirror fitting plate concave a up and install it to the meter bracket EAS14B1001 REMOVING THE UPPER TAIL COVER 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Passenger seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Upper tail cover 1 a Remove the bolt on the upper tail cover b Remove the quick fasteners on the upper tail cover c Sli...

Page 171: ...tall Passenger seat Refer to GENERAL CHASSIS on page 4 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1054 INSTALLING THE TAIL BRAKE LIGHT 1 Install Tail brake light 1 TIP Fit the tail brake light tabs a into the holes b of the lower tail cover 2 EAS14B1056 ADJUSTING THE RIDER FOOTRESTS 1 Remove Rider footrest right and left WARNING EWA14B1018 When removing the right rider footrest 1 be c...

Page 172: ... set them on the same level e Install the rider footrest bolts TIP Install the end a of the exhaust chamber cover 1 within the range b of the exhaust chamber upper cover 2 as shown in the illustration After adjusting the right rider footrest adjust the rear brake pedal and rear brake light switch Refer to ADJUSTING THE REAR DISC BRAKE on page 3 16 and ADJUSTING THE REAR BRAKE LIGHT SWITCH on page ...

Page 173: ...older 1 2 Right brake hose holder 1 3 Left front brake caliper 1 4 Right front brake caliper 1 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Collar left and right 2 9 Dust cover left and right 2 10 Front wheel 1 11 Front brake disc left and right 2 For installation reverse the removal proce dure ...

Page 174: ...ONT WHEEL 4 19 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 175: ... on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 19 and CHECKING THE WHEELS on page 3 19 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings Oil...

Page 176: ...ust 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 the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an ...

Page 177: ...xle Oil seal lips 2 Lift the wheel up between the fork legs 3 Insert the wheel axle TIP Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Tighten Front wheel axle bolt Front wheel axle pinch bolt Refer to CHASSIS TIGHTENING TORQUES on page 2 20 ECA14B1002 Before tightening the wheel axle push down hard on th...

Page 178: ...0 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 TIP Make sure that there is enough space between the brake pads before installing the brake cali pers on to the brake discs ...

Page 179: ...liper Refer to REAR BRAKE on page 4 43 1 Locknut left and right 2 Loosen 2 Adjusting bolt left and right 2 Loosen 3 Rear wheel axle nut 1 4 Washer 1 5 Rear wheel axle 1 6 Adjusting block left 1 7 Adjusting block right 1 8 Rear wheel 1 9 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 180: ...ocket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Dust cover 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal proce dure ...

Page 181: ...REAR WHEEL 4 26 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 182: ...lts 2 4 Remove Wheel axle nut 1 Wheel axle Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 20 2 Check Tire Rear wheel Damage wear ...

Page 183: ...in a crisscross pattern 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 WHEEL STATIC BALANCE on page 4 21 EAS22160 INSTALLING THE REAR WHEEL 1 Lubricat...

Page 184: ...A13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 Rear wheel axle nut 150 Nm 15 m kgf 110 ft lbf Rear brake caliper bolt front side 27 Nm 2 7 m kgf 19 ft lbf Rear brake caliper bolt rear side 22 Nm 2 2 m kgf 16 ft lbf ...

Page 185: ...arts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Brake pad kit 1 7 Bleed screw 1 For installation reverse the removal proce dure ...

Page 186: ...servoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch connector 2 Disconnect 9 Union bolt 1 10 Washer 2 11 Brake hose 1 12 Brake master cylinder holder 1 13 Brake master cylinder 1 14 Front brake light switch 1 For installation reverse the removal proce du...

Page 187: ...4 32 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For installation reverse the removal proce dure ...

Page 188: ... remove Q ty Remarks The following procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 1 Union bolt 1 2 Washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 189: ... Job Parts to remove Q ty Remarks 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Brake pad kit 1 5 Brake caliper piston 6 6 Brake caliper piston dust seal 6 7 Brake caliper piston seal 6 8 Bleed screw 1 For installation reverse the removal proce dure ...

Page 190: ...S22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 18 2 Check Brake discs 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 ...

Page 191: ...f If the brake disc deflection cannot be brought within specification replace the brake disc 6 Install Front wheel Refer to FRONT WHEEL on page 4 18 EAS14B1004 REPLACING THE FRONT BRAKE PADS TIP When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove Brake hose holder 1 Brake caliper 2 2 Remove Brake pad clips 1 Brake pad pins 2 Br...

Page 192: ... the brake pad springs must point in the direction of disc rotation 6 Install Brake pad pins Brake pad clips Brake caliper 7 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 15 8 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE S...

Page 193: ...e of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper WARNING EWA14B1002 Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove the brake caliper piston dust seals and brake caliper piston seals d Cover the left piston with a cloth so that air does not leak from it and repeat the above procedure a...

Page 194: ...aliper is disassem bled replace the brake caliper piston dust seals and brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake calipers 1 Install Brake pads Brake pad springs Brake pad pins 2 Install Brake caliper 1 Copper washers Brake hose 2 Union bolt 3 Brake hose holder WARNING EWA13530 Proper brake hose routing is essentia...

Page 195: ...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 15 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylin der drain the brake fluid from ...

Page 196: ... BRAKE MASTER CYLINDER 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 First tighten the upper bolt then the lower bolt 2 Install Washers Brake hose Union bolt WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 TIP While holding the br...

Page 197: ...t enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock 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 17 5 Check Brake fluid level Below the minimum level mark a Add the ...

Page 198: ...ving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad kit 1 6 Bleed screw 1 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 199: ...IC BRAKE SYSTEM on page 3 17 1 Footrest plate 1 2 Brake fluid reservoir cap 1 3 Rear brake fluid reservoir diaphragm holder 1 4 Rear brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Washer 2 9 Brake hose 1 10 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 200: ...linder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Adjusting nut 1 3 Brake master cylinder kit 1 4 Dust cover 1 5 Circlip 1 6 Hose joint 1 7 O ring 1 8 Brake master cylinder body 1 For installation reverse the removal proce dure ...

Page 201: ...REAR BRAKE 4 46 Removing the rear brake calipers Order Job Parts to remove Q ty Remarks 1 Union bolt 1 2 Washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 202: ...s to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad kit 1 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 For installation reverse the removal proce dure ...

Page 203: ...KING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 24 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 35 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification ...

Page 204: ...stall a new brake pad shim 3 onto each new brake pad 4 5 Install Brake pad pin Screw plug Brake caliper 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 ...

Page 205: ...550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton c Remove the brake caliper piston dust seal and brake caliper piston seal EAS22640 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 S...

Page 206: ... dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Brake caliper 1 temporarily Washers Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on...

Page 207: ...lean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYS...

Page 208: ...MASTER CYLINDER 1 Install Washers Brake hoses Union bolt WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 ECA14B1004 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown Face the brake hose paint mark b to the rear master cylinder and install so that the p...

Page 209: ...ed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 6 Adjust Brake pedal position ...

Page 210: ...fer to GENERAL CHASSIS on page 4 1 Front cowling Refer to GENERAL CHASSIS on page 4 1 Front brake master cylinder Refer to FRONT BRAKE on page 4 30 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 1 Grip end 2 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever assembly 1 7 Throttle cable h...

Page 211: ... 1 12 Handlebar pinch bolt 2 Loosen 13 Handlebar bolt 2 Loosen 14 Upper bracket pinch bolt 2 Loosen 15 Steering stem nut 1 16 Main switch coupler 2 Disconnect 17 Immobilizer unit coupler 1 Disconnect 18 Clutch cable guide 1 19 Upper bracket 1 20 Left handlebar 1 21 Right handlebar 1 22 Grip end damper 2 For installation reverse the removal proce dure ...

Page 212: ... Left handlebar 1 Right handlebar 2 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22900 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Right handlebar switch 1 TIP Align the projection a on the rig...

Page 213: ...rip Grip end a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA14B1007 Do not touch the handlebar grip until the rubber adhesive has fully dried TIP When installing the handlebar grip keep the clearance of 1 0 3 0 mm 0 04 0 12 in between the handle...

Page 214: ...e front fork legs Side cowling Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 18 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 For installation reverse the removal proce dure ...

Page 215: ...remove Q ty Remarks The following procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Nut 1 5 Spacer 1 6 Upper spring seat 1 7 Fork spring 1 8 Lower spring seat 1 9 Outer tube 1 10 Dust seal 1 11 Oil seal clip 1 12 Oil seal 1 13 Washer 1 ...

Page 216: ...e front fork legs Order Job Parts to remove Q ty Remarks 14 Damper rod assembly 1 15 Damper adjusting rod 1 16 Damper adjusting valve 1 17 Damper adjusting valve spring 1 18 Inner tube 1 For installation reverse the removal proce dure ...

Page 217: ...page 4 30 Front wheel Refer to FRONT WHEEL on page 4 18 Side cowlings Refer to GENERAL CHASSIS on page 4 1 3 Loosen Handlebar pinch bolt 1 Upper bracket pinch bolts 2 Handlebar bolt 3 Cap bolt 4 Lower bracket pinch bolts 5 WARNING EWA14B1009 Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove Front fork leg EAS14B1007 DISASSEMBLING THE FRONT FORK LEGS The f...

Page 218: ...p bolt e Remove the rod holder and fork spring compressor f Remove the nut and spacer 3 Drain Fork oil TIP Stroke the damper rod 1 several times while draining the fork oil 4 Remove Dust seal Oil seal clip 1 with a flat head screwdriver Oil seal Washer 5 Remove Damper rod assembly ECA14B1048 For the damper rod assembly the right side is used for the rebound operation and left side for the compress...

Page 219: ...g and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check Cap bolt 1 Cap bolt collar projections 2 Cracks damage Replace EAS14B1008 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA14B1010 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a...

Page 220: ...icate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil 5 Install Outer tube to the inner tube 6 Install Washer Oil seal 1 with the fork seal driver 2 7 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Recommended oil Suspension oil M1 or equiva lent Damper rod assembly 75 Nm 7 5 m kgf 54 ft lbf Damp...

Page 221: ...ter the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly because the fork oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Fork seal driver 90890 01442 Adjustable fork seal driver 36 ...

Page 222: ...g seat c Install the fork spring TIP Install the spring with the smaller diameter a facing up A d Install the upper spring seat e Install the spacer f Install the nut g Reinstall the rod puller attachment h Press down on the spacer with the fork spring compressor 1 i Pull up the rod puller and install the rod holder 2 between the nut 3 and the spacer 4 TIP Use the side of the rod holder that is ma...

Page 223: ...16 in or less o Remove the rod holder and fork spring compressor 16 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts EAS14B1009 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 I...

Page 224: ...fer to CABLE ROUTING on page 2 49 5 Install Plastic band 1 TIP Fasten the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 24 Cap bolt 20 Nm 2 0 m kgf 14 ft lbf Handlebar bolt 13 Nm 1 3 m kgf 9 4 ft lbf Handlebar pinch bolt 16 Nm 1 6 m kgf 11 ft lbf Upper bracket pi...

Page 225: ...on page 4 1 Front fork legs Refer to FRONT FORK on page 4 59 Handlebars Refer to HANDLEBARS on page 4 55 1 Horn lead connector 2 Disconnect 2 Horn 1 3 Front brake hose joint 1 4 Front brake hose joint bracket 1 5 Lower bracket cover 1 6 Steering damper coupler 1 Disconnect 7 Cable guide 1 8 Steering damper 1 9 Steering damper bracket 1 10 Lock washer 1 11 Upper ring nut 1 12 Rubber washer 1 ...

Page 226: ...er ring nut 1 14 Lower bracket 1 15 Upper bearing cover 1 16 Upper bearing inner race 1 17 Upper bearing 1 18 Lower bearing 1 19 Lower bearing inner race 1 20 Lower bearing dust seal 1 21 Upper bearing outer race 1 22 Lower bearing outer race 1 For installation reverse the removal proce dure ...

Page 227: ...earings Bearing races a Remove the bearing races 1 from the steering head pipe 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 dust seal and new bearing races ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whene...

Page 228: ...ARS on page 4 55 TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 68 TIP Temporarily tighten the upper and lower bracket pinch bolts EAS14B1005 CHECKING THE STEERING DAMPER 1 Check Steering damper body Damage oil leaks Replace It replace with the assembly Steering damper rod Bends scratch Replace It replace with the assembly ...

Page 229: ... Passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Muffler Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm collar 1 2 Connecting arm 1 3 Relay arm collar 1 4 Relay arm 1 5 Collar 3 6 Oil seal 6 7 Bearing 4 8 Rear shock absorber assembly 1 9 Rear shock absorber assembly bracket 1 10 Exhaust chamber stay 1 For installation reverse the removal proce dur...

Page 230: ...se the gas pressure drill a 2 0 3 0 mm 0 08 0 12 in hole through the rear shock absorber at a point 40 mm 1 57 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it fal...

Page 231: ...ll Bearing 1 Oil seals 2 to the relay arm Relay arm 3 Connecting arm 4 TIP When installing the oil seals to the relay arm or connecting arm face the character stamp of the oil seals outside EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Collars Bearings 2 Install Rear shock absorber assembly TIP Install the rear shock absorber assembly lower bolt from the left 3 Tighten Rear shoc...

Page 232: ...IP When installing the connecting arm lift up the swingarm 5 Tighten Connecting arm and swingarm nut Rear shock absorber assembly bracket and frame nut 92 Nm 9 2 m kgf 66 ft lbf Rear shock absorber assembly lower nut 40 Nm 4 0 m kgf 29 ft lbf Connecting arm and swingarm nut 40 Nm 4 0 m kgf 29 ft lbf ...

Page 233: ...4 24 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 74 1 Drive chain guard 1 2 Rear fender 1 3 Left footrest 1 4 Drive chain guide 1 5 Brake hose holder 1 6 Pivot shaft nut washer 1 1 7 Pivot shaft ring nut washer 1 1 8 Pivot shaft 1 9 Swingarm 1 10 Drive chain 1 11 Collar 1 12 Dust cover 1 13 Spacer 1 ...

Page 234: ...SWINGARM 4 79 Removing the swingarm Order Job Parts to remove Q ty Remarks 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Bearing 2 For installation reverse the removal proce dure ...

Page 235: ...ide play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacer bearings collar and dust cover d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacer bearings collar and dust cover 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN o...

Page 236: ...ft 3 Wash Pivot shaft Dust cover Spacer Washers Bearings 4 Check Dust cover 1 Spacer 2 Collar 3 Bearings 4 Damage wear Replace EAS14B1011 INSTALLING THE SWINGARM 1 Lubricate Bearings Dust cover Pivot shaft 2 Install Bearings 1 Bearing 2 Circlip 3 Oil seal 4 Damper rod holder 22 mm 90890 01365 Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease Installed depth of b...

Page 237: ...HE DRIVE CHAIN SLACK on page 3 21 5 Dust cover 6 Collar 7 Swingarm 8 Pivot shaft A Left side B Right side Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut 65 Nm 6 5 m kgf 47 ft lbf Ring nut wrench 90890 01507 YM 01507 Pivot shaft nut 105 Nm 10 5 m kgf 75 ft lbf Drive chain slack when adjust ing the drive chain 25 0 35 0 mm 0 98 1 38 in Drive chain slac...

Page 238: ...Remarks Drive chain Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Shift pedal 1 5 Drive sprocket cover 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive chain guide drive sprocket side 1 9 Drive sprocket 1 10 Drive chain 1 For installation reverse the removal proce dure ...

Page 239: ...cket as a set TIP While measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and...

Page 240: ...teeth Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 28 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 28 EAS23490 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA14B1023 Be sure to put on safety goggles when working a When press fitting the c...

Page 241: ...l a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within t...

Page 242: ...CHAIN DRIVE 4 87 ...

Page 243: ...ING THE CYLINDER HEAD 5 26 INSTALLING THE CYLINDER HEAD 5 26 VALVES AND VALVE SPRINGS 5 28 REMOVING THE VALVES 5 30 CHECKING THE VALVES AND VALVE GUIDES 5 31 CHECKING THE VALVE SEATS 5 32 CHECKING THE VALVE SPRINGS 5 34 CHECKING THE VALVE LIFTERS 5 35 INSTALLING THE VALVES 5 35 GENERATOR 5 37 REMOVING THE GENERATOR 5 38 INSTALLING THE GENERATOR 5 38 STARTER CLUTCH 5 40 REMOVING THE STARTER CLUTCH ...

Page 244: ...RY DRIVEN GEAR 5 66 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 66 INSTALLING THE CLUTCH 5 66 SHIFT SHAFT 5 69 CHECKING THE SHIFT SHAFT 5 70 CHECKING THE STOPPER LEVER 5 70 INSTALLING THE SHIFT SHAFT 5 70 CRANKCASE 5 71 DISASSEMBLING THE CRANKCASE 5 73 CHECKING THE CRANKCASE 5 73 ASSEMBLING THE CRANKCASE 5 73 CONNECTING RODS AND PISTONS 5 75 REMOVING THE CONNECTING RODS AND PISTONS 5 76 CHECKING ...

Page 245: ... 5 92 REMOVING THE TRANSMISSION 5 96 CHECKING THE SHIFT FORKS 5 96 CHECKING THE SHIFT DRUM ASSEMBLY 5 97 CHECKING THE TRANSMISSION 5 97 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 98 INSTALLING THE TRANSMISSION 5 98 ...

Page 246: ...sure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compres sion gauge stabilizes WARNING EWA14B1017 To prevent sparking the plug remove all ignition coil couplers before cranking the engine TIP The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg...

Page 247: ...tallation reverse the removal proce dure Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Replace Same as without oil Piston valves or cyl inder head gasket possibly defective Replace Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 248: ...on page 4 1 Side cowling Refer to GENERAL CHASSIS on page 4 1 Rear brake master cylinder Refer to REAR BRAKE on page 4 43 Radiator lower bracket Refer to RADIATOR on page 6 1 1 Left muffler cover 1 2 Left muffler pipe cover 1 3 Left muffler pipe protector clamp 1 Loosen 4 Left muffler pipe protector 1 5 Right muffler cover 1 6 Right muffler pipe cover 1 7 Right muffler pipe protector clamp 1 Loose...

Page 249: ...ght muffler clamp 1 Loosen 13 Right muffler 1 14 Right muffler gasket 1 15 Rear brake light switch coupler 1 Disconnect 16 Right footrest assembly 1 17 Exhaust chamber cover 1 18 Rear brake light switch 1 19 O2 sensor lead coupler 1 Disconnect 20 O2 sensor 1 21 Exhaust chamber clamp 1 22 Exhaust chamber 1 23 Exhaust chamber gasket 1 24 Collar 1 ...

Page 250: ...b Parts to remove Q ty Remarks 25 Exhaust chamber protector 1 26 Exhaust chamber pipe protector clamp 1 Loosen 27 Exhaust chamber pipe protector 1 28 Exhaust chamber bracket 1 29 Exhaust pipe 1 30 Exhaust pipe gasket 4 For installation reverse the removal proce dure ...

Page 251: ...ing Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 Radiator Refer to RADIATOR on page 6 1 Shift pedal Refer to CHAIN DRIVE on page 4 83 Drive sprocket Refer to CHAIN DRIVE on page 4 83 Throttle body assembly Refer to THROTTLE BODIES on page 7 12 1 Sub wire harness coupler 1 Disconnect 2 Crank...

Page 252: ...rts to remove Q ty Remarks 5 Speed sensor lead coupler 1 Disconnect 6 Oil level switch lead coupler 1 Disconnect 7 Gear position sensor coupler 2 Disconnect 8 Engine ground lead 2 Disconnect 9 Clutch cable 1 Disconnect For installation reverse the removal proce dure ...

Page 253: ...ght inner panel bracket 1 5 Sidestand assembly 1 6 Sidestand switch 1 7 Holder 1 8 Sidestand switch bracket 1 9 Engine mounting bolt front right side 1 10 Engine mount collar front right side 2 11 Engine mount collar front right side 1 12 Engine mounting bolt front left side 1 13 Left engine mount collar 1 14 Left engine mount damper 1 15 Engine mount nut rear upper side 1 ...

Page 254: ...er Job Parts to remove Q ty Remarks 16 Engine mount nut rear lower side 1 17 Engine mount bolt rear upper side 1 18 Engine mount bolt rear lower side 1 19 Engine 1 20 Engine mount adjusting bolt 2 For installation reverse the removal proce dure ...

Page 255: ...together with damper 2 Engine mounting bolt front left side 3 temporary tighten TIP When installing the engine mount collar front left side set the damper toward the engine 5 Install Engine mount collars front right side 1 Engine mount collar front right side 2 Engine mounting bolt front right side 3 temporary tighten 6 Tighten Engine mount adjusting bolts TIP Use the pivot shaft wrench 1 and pivo...

Page 256: ...ht footrest assembly Refer to ADJUSTING THE RIDER FOOTRESTS on page 4 16 2 Install Muffler gasket 1 to muffler Muffler TIP When installing the muffler gasket set the surface a with the carbon to the back When installing the catalyst pipe assembly and muffler clamp tip of the tab b should not contact the edge of the muffler gasket Engine mounting nut rear lower side 51 Nm 5 1 m kgf 37 ft lbf Engine...

Page 257: ...ENGINE REMOVAL 5 12 Installed depth of gasket c 3 5 mm 0 14 in ...

Page 258: ...fer to RADIATOR on page 6 1 Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 21 Throttle body Refer to THROTTLE BODIES on page 7 12 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 1 Ignition coil coupler 4 Disconnect 2 Ignition coil 4 3 Spark plug 4 4 Cylinder identification sensor coupler 1 Disconnect 5 Cylinder identification sensor 1 6 O ring 1 7 Cylinder head cover 1...

Page 259: ...CAMSHAFTS 5 14 For installation reverse the removal proce dure Removing the cylinder head cover Order Job Parts to remove Q ty Remarks ...

Page 260: ...e 5 37 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 3 4 Exhaust camshaft cap 3 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Dowel pin 2 10 Intake side timing chain guide 1 11 Exhaust side timing chain guide 1 12 Pickup rotor 1 Refer to PICKUP ROTOR on page 5 43 13 Timing chain 1 ...

Page 261: ...CAMSHAFTS 5 16 Removing the camshafts Order Job Parts to remove Q ty Remarks 14 Crankshaft sprocket 1 15 Collar 1 16 Straight key 1 For installation reverse the removal proce dure ...

Page 262: ...b TIP You can check that the 1 piston is at BTDC 105 by checking to see that the intake cam shaft sprocket timing mark c and exhaust camshaft sprocket timing mark d are aligned with the cylinder head surface e 3 Remove Timing chain tensioner 1 Gasket 4 Remove Camshaft caps 1 ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a ...

Page 263: ...eplace the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft 3 Measure Camshaft runout Out of specification Replace Camshaft lobe dimension limit Intake A 37 350 37 450 mm 1 4705 1 4744 in Limit 37 250 mm 1 4665 in Intake B 28 034 28 134 mm 1 1037 1 1076 in Limit 27 934 mm 1 0998 in Exhaust A 36 450 36 550 mm 1 4350 1 4390 in Limit 36 350 mm 1 4311 in E...

Page 264: ...e the camshaft caps and then mea sure the width of the Plastigauge 2 5 Measure Camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylin der head and the camshaft caps as a set EAS23870 CHECKING THE TIMING CHAIN AND SPROCKET 1 Check Timing chain Damage stiffness Replace the timing chain camshaft sprockets and crankshaft sprocket as a set 2 Check ...

Page 265: ...he timing chain tensioner rod mount clip 5 into groove 6 and lock the timing chain tensioner rod c Push the timing chain tensioner rod in direction c d Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction d If not smooth replace the timing chain ten sioner assembly EAS24000 INSTALLING THE CAMSHAFTS 1 Install Straight key 1 Collar ...

Page 266: ... at BTDC 105 align the K mark a with the crankcase mating surface b 5 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 ECA14B1012 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket...

Page 267: ...t side camshaft cap mark Make sure the arrow mark a on each cam shaft points towards the right side of the engine When installing the camshaft cap face the hole with the screw thread b on the cam shaft cap to the left side of the engine 8 Install Camshaft cap bolts ECA14B1011 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylin...

Page 268: ...iming mark c Make sure the punch mark c on the camshaft sprocket is aligned with the cyl inder head mating surface d Out of alignment Adjust Refer to the installation steps above 12 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 5 13 Install Pickup coil rotor cover 2 Refer to PICKUP ROTOR on page 5 43 14 Install Cylinder head cover gasket Cylin...

Page 269: ...CAMSHAFTS 5 24 Tighten the cylinder head cover bolts stages and in a crisscross pattern Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 270: ...ove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 3 Intake camshaft Refer to CAMSHAFTS on page 5 13 Exhaust camshaft Refer to CAMSHAFTS on page 5 13 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure ...

Page 271: ...s Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder h...

Page 272: ...hten Cylinder head nuts 1 10 Cylinder head bolts 11 12 TIP Tighten the cylinder head nuts in the tightening sequence as shown and torque them in 3 stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAM SHAFTS on page 5 20 Cylinder head nut 1st 10 Nm 1 0 m kgf 7 2 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf 3rd Nut 1 7 10 115 125 Nut 8 9 130 140 Cylinder head bolt 12 Nm 1 2 m kgf 8 ...

Page 273: ...gs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 25 1 Intake valve lifter 8 2 Intake valve pad 8 3 Intake valve cotter 16 4 Intake valve spring retainer 8 5 Intake valve spring 8 6 Intake valve 8 7 Intake valve stem seal 8 8 Intake valve spring seat 8 9 Intake valve guide 8 ...

Page 274: ...ove Q ty Remarks 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve spring retainer 8 14 Exhaust valve spring 8 15 Exhaust valve 8 16 Exhaust valve stem seal 8 17 Exhaust valve spring seat 8 18 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 275: ...alve seat width Refer to CHECKING THE VALVE SEATS on page 5 32 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 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 4 Remove Valve spring re...

Page 276: ...uide remover 1 b Install the new valve guide 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 obtain 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 s...

Page 277: ...liminate 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 cylin der head Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide installer ...

Page 278: ...placing the intake valves replace the intake valves without lapping the valve seats and valve faces When replacing the cylinder head or intake valve guides use new valves to lap the valve seats and then replace them with new intake valves a Apply a coarse lapping compound a to the valve face ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply m...

Page 279: ...nd lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring Valve spring free length Free length intake 39 33 mm 1 55 in Limit 37 36 mm 1 47 in Free length exhaust 37 96 m...

Page 280: ...Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its origi nal place Refer to the following embossed marks Intake valve Blue paint mark Exhaust valve 14B Install the valve springs with the larger pitch a facing up When...

Page 281: ...itting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach...

Page 282: ...r case Refer to AIR FILTER CASE on page 7 5 Side cowling Refer to GENERAL CHASSIS on page 4 1 Stator coil lead coupler Refer to GENERAL CHASSIS on page 4 1 1 Generator cover 1 2 Generator cover gasket 1 3 Dowel pin 2 4 Washer 1 5 Generator rotor 1 6 Stator coil lead holder 1 7 Stator coil assembly 1 For installation reverse the removal proce dure ...

Page 283: ...r Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 3 Tighten Generator rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A Rotor puller 2K7 85555 00...

Page 284: ...GENERATOR 5 39 4 Apply Sealant onto the stator coil lead grommet 1 Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 285: ...ving the starter clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 59 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch assembly 1 4 Starter idle gear 1 For installation reverse the removal proce dure ...

Page 286: ...h gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the clutch housing assembly 2 and hold the clutch housing assembly b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terclockwise B it should turn freel...

Page 287: ...STARTER CLUTCH 5 42 Fix the flat surface of the clutch housing assembly with the sheave holder Sheave holder 90890 01701 Primary clutch holder YS 01880 A ...

Page 288: ...tor cover Refer to GENERATOR on page 5 37 Air filter case Refer to AIR FILTER CASE on page 7 5 1 Timing check bolt 1 2 Pickup rotor cover 1 1 3 O ring 1 4 Crankshaft position sensor coupler 1 Disconnect 5 Pickup rotor cover 2 1 6 Pickup rotor cover 2 gasket 1 7 Crankshaft position sensor 1 8 Pickup rotor 1 For installation reverse the removal proce dure ...

Page 289: ... the pickup rotor align the straight key a with the groove b on the pickup rotor Face the K mark on the pickup rotor outer side of the vehicle and install 2 Tighten Pickup rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet 1 Sheave holder 90890 01701 Primary clutch holder YS 01...

Page 290: ...PICKUP ROTOR 5 45 Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 291: ...d Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 12 Engine outlet pipe Refer to THERMOSTAT on page 6 8 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 292: ...r motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 Gasket 2 8 Brush holder 1 9 O ring 1 10 Rear cover 1 For installation reverse the removal proce dure ...

Page 293: ...sure Armature assembly resistances commu tator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the digital circuit tester b If any resistance is out of specification replace the starter motor 5 Measure Brush length a Out of specification Replace the brush holder Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Digital circuit...

Page 294: ...oove portion at the side of the brush b Insert the armature assembly 3 into the brush holder 4 and push the brush 5 inside until it touches the armature assem bly 2 Install Rear cover 1 TIP Align the tab a on the brush holder 2 with the tab b in the rear cover 3 Install Washer Nut 1 4 Install Starter motor yoke 1 Gaskets 2 Front cover 3 Starter motor assembling bolts 4 Brush spring force 5 28 7 92...

Page 295: ...ELECTRIC STARTER 5 50 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers ...

Page 296: ...GING THE ENGINE OIL on page 3 29 Fuel tank Refer to FUEL TANK on page 7 1 Coolant reservoir Refer to RADIATOR on page 6 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Clutch assembly Refer to CLUTCH on page 5 59 Water pump inlet pipe Refer to RADIATOR on page 6 1 Water pump outlet pipe Refer to OIL COOLER on page 6 5 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch 1 3 Oil level...

Page 297: ...1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 1 11 Relief valve assembly 1 12 Oil water pump assembly drive chain guide 1 13 Collar 1 14 Oil water pump assembly drive sprocket 1 15 Washer 1 16 Oil water pump assembly drive chain 1 17 Dowel pin 1 18 Oil water pump assembly 1 For installation reverse the removal proce dure ...

Page 298: ...p Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Circlip 1 3 Oil pump housing 1 4 Bearing 1 5 Dowel pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For installation reverse the removal proce dure ...

Page 299: ...p assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Cracks damage wear Replace Oil pump housing 2 Cracks damage wear Replace the oil water pump assembly 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clear ance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil water p...

Page 300: ...age wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent 1 Inner rotor 2 Outer rotor 3 Oil pump housin...

Page 301: ...ump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 54 EAS25030 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install O ring onto the lower crankcase Oil water pump assembly 1 Dowel pin Bolts 2 2 Install Washer Oil water pump assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar TIP Install the oil water pump assembly drive chain 1 onto the oil water pump assem...

Page 302: ...bly 1 O ring Oil strainer 2 O ring Oil pipe 3 O rings Drain pipe 4 O rings EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Oil pan gasket Oil pan Oil level switch lead holder Oil level switch O ring Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil delivery pipe 1 bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Relief valve assembly bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 303: ...drain bolt Gasket TIP Tighten the oil pan bolts in stages and in a crisscross pattern Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil level switch bolt 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf New ...

Page 304: ...e clutch cover Order Job Parts to remove Q ty Remarks Engine oil Drain 1 Pull lever cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 3 6 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 305: ...e pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal proce dure ...

Page 306: ...ssion spring 6 2 Pressure plate 1 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 1 1 11 Clutch boss nut 1 12 Spring 3 13 Clutch boss 1 14 Pressure plate 2 1 15 Conical spring washer 1 ...

Page 307: ...CLUTCH 5 62 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Clutch housing assembly 1 18 Bearing 1 19 Washer 1 For installation reverse the removal proce dure ...

Page 308: ...ve Compression spring bolts 1 Compression springs Pressure plate 1 2 Pull rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate 3 5 Straighten the clutch boss nut rib a 6 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 7 Remove Clutch boss nut Springs Clutch boss Universal...

Page 309: ...plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure assembly width a of the friction plates and clutch plates Out of specification Adjust TIP Perform the thickness measurement without applying the oil This step should be performed only if the fric tion plates and clutch plates were replaced To measure the total width of the fri...

Page 310: ...NG 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing TIP Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines ...

Page 311: ...rankshaft as a set Excessive noise during operation Replace the clutch housing and crank shaft as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft as a set 2 Check Pull rod bearing Damage wear Replace EAS25240 INSTALLING THE CLUTCH 1 Install Washer Bearing Clutch housing ass...

Page 312: ...utch boss nut at a cutout a in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align a projection on the friction plate with the punch...

Page 313: ...TE to the threads of only the clutch cover bolts b shown in the illustration Tighten the clutch cover bolts in stages and in a crisscross pattern 9 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP The end of the pull lever should be closest to the clutch cover match mark a when there is no free play of the pull lever Make sure that the pull rod teeth and pull lever shaft pinion gear are...

Page 314: ...CHAIN DRIVE on page 4 83 Clutch assembly Refer to CLUTCH on page 5 59 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Bearing 1 13 Oil seal 1 14 Bearing 1 For installation reverse the removal proce dure ...

Page 315: ...EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum se...

Page 316: ... page 5 25 Starter motor Refer to ELECTRIC STARTER on page 5 46 Stator coil assembly Refer to GENERATOR on page 5 37 Pickup rotor Refer to PICKUP ROTOR on page 5 43 Clutch housing assembly Refer to CLUTCH on page 5 59 Shift shaft assembly Refer to SHIFT SHAFT on page 5 69 Oil water pump assembly Refer to OIL PUMP on page 5 51 1 Clutch cable holder 1 2 Main gallery plug 1 2 3 Main gallery plug 2 1 ...

Page 317: ...torque Separating the crankcase Order Job Parts to remove Q ty Remarks 8 Crankcase breather cover 1 9 Crankcase breather cover gasket 1 10 Crankcase breather case 1 11 Crankcase breather case gasket 1 12 Lower crankcase 1 13 Dowel pin 3 14 Crankcase baffle plate 4 For installation reverse the removal proce dure ...

Page 318: ...he crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25650 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft journal bearings with the recommended lubricant 2 Apply Sealant onto the crankcase mating surfaces TIP Do not allow any sealant t...

Page 319: ...ng order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA14B1030 If the crankcase bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Instead replace the crankcase bolt with a new one and perform the procedure again ECA14B1043 Do not use a torque wrench to tighten the crankcase bolt to the specified angle TIP Tighten the b...

Page 320: ... Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 71 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 13 Dowel pin 2 For installation reverse the removal proce dure ...

Page 321: ...o drive the piston pin out TIP For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are debarred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the...

Page 322: ... replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limi...

Page 323: ...e Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the pis ton Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in a 10 mm 0 4 in Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit ...

Page 324: ... end lower bear ing into the connecting rod cap TIP Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves ECA14B1041 Tighten the connecting rod bolts using the plastic region tightening angle method Always install new bolts TIP Replace the connecting ...

Page 325: ...nd install these parts to the crankshaft with the big end bearing kept in the current condi tion TIP Do not move the connecting rod or crank shaft until the clearance measurement has been completed Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod Make sure the Y marks b on the connect ing rods face towards the left side of th...

Page 326: ...g rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 TIP The numbers A stamped into the crank shaft web and the numbers 1 on the con necting rods are used to determine the replacement big end bearings sizes P1 P4 refer...

Page 327: ...ing rod bolts with new ones b Clean the connecting rod bolts and lubri cate the bolt threads and seats with molyb denum disulfide oil c After installing the big end bearing assem ble the connecting rod and connecting rod cap without installing them onto the crank shaft d Tighten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface...

Page 328: ...cate Piston Piston rings Cylinder with the recommended lubricant 6 Offset Piston ring end gaps 7 Lubricate Crankshaft pins Connecting rod big end bearing inner sur face with the recommended lubricant 8 Check Cylinder stud bolts 9 Install Piston assemblies 1 into the cylinder 2 ECA14B1040 If the projection a of the piston installing tool damages you cannot use it Please handle with care New Recomme...

Page 329: ...n b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and bearing surface of the connect ing rod bolt and connecting rod cap 11 Tighten Connecting rod bolts 1 TIP Tighten the connecting rod bolts using the fol lowing procedure a Tighten the connecting rod bolts with a torque wrench b Put a mark 1 on the corn...

Page 330: ...t loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle d After the installation check that the section shown a is flush with each other by touch ing the surface ...

Page 331: ...age 5 71 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 76 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft 1 5 Crankshaft journal lower bearing 5 6 Crankshaft journal upper bearing 5 7 Oil nozzle 4 For installation reverse the removal proce dure ...

Page 332: ...urfaces Bearing surfaces Scratches wear Replace the crank shaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must ...

Page 333: ...nkshaft journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crank shaft web and the numbers B stamped into the lower crankcase are used to d...

Page 334: ...al bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing por tions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the ...

Page 335: ...r shaft journal bearings 4 Select Balancer shaft journal bearings J1 J4 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bear ing sizes J1 J4 refer to the bearings shown in the bal ancer shaft illustration If J1 J4 are the same use the same size for all of the bearings For example i...

Page 336: ...NCER ASSEMBLY 1 Install Balancer journal upper bearings into the upper crankcase Balancer journal lower bearings into the lower crankcase TIP Align the projections a on the balancer jour nal bearings 1 with the notches b in the crankcases Be sure to install each balancer journal bear ing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the bala...

Page 337: ...ankcase Separate Refer to CRANKCASE on page 5 71 1 Drive axle assembly 1 2 Shift drum retainer 2 3 Spring 2 4 Shift fork guide bar 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum assembly 1 8 Shift fork C 1 9 Main axle assembly 1 10 Oil delivery pipe 2 1 11 O ring 3 12 Oil baffle plate 1 13 Bearing 2 For installation reverse the removal proce dure ...

Page 338: ...pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd 4th pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For installation reverse the removal proce dure ...

Page 339: ...arts to remove Q ty Remarks 1 Circlip 1 2 Bearing 1 3 Washer 1 4 1st wheel gear 1 5 Collar 1 6 5th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Collar 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Collar 1 15 Washer 1 ...

Page 340: ...sembly Order Job Parts to remove Q ty Remarks 16 Circlip 1 17 6th wheel gear 1 18 Circlip 1 19 Washer 1 20 2nd wheel gear 1 21 Collar 1 22 Collar 1 23 Oil seal 1 24 Circlip 1 25 Bearing 1 26 Drive axle 1 For installation reverse the removal proce dure ...

Page 341: ...lts until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 2 1 Bearings 2 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guid...

Page 342: ...E TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective ...

Page 343: ... lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer EAS26350 INSTALLING THE TRANSMISSION 1 Install Bearing 1 Oil delivery ...

Page 344: ... 4 Install Shift fork R 1 Shift fork L 2 Shift fork guide bar Springs Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the drive axle bearing circlip 4 is ...

Page 345: ... 6 5 CHECKING THE OIL COOLER 6 7 INSTALLING THE OIL COOLER 6 7 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 10 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 11 WATER PUMP 6 12 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 ...

Page 346: ... Side cowling Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 1 Radiator cap 1 2 Coolant reservoir hose 1 Disconnect 3 Radiator fan motor coupler 2 Disconnect 4 Radiator outlet hose 1 5 Water pump bypass hose 1 Disconnect 6 Water pump inlet pipe 1 7 Drain bolt 1 8 Copper washer 1 9 O ring 1 10 Oil cooler outlet hose 1 Disconnect 11 Radiator 1 ...

Page 347: ... Job Parts to remove Q ty Remarks 12 Radiator bracket 1 13 Radiator fan 2 14 Thermostat bypass hose 2 1 Disconnect 15 Thermostat bypass hose 3 1 16 Radiator inlet pipe 1 17 Radiator inlet hose 1 For installation reverse the removal proce dure ...

Page 348: ...Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Radia...

Page 349: ... 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 350: ...ling Refer to GENERAL CHASSIS on page 4 1 Lower cowling Refer to GENERAL CHASSIS on page 4 1 ECU Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Oil cooler outlet hose 1 2 Oil cooler union bolt 1 3 Gasket 1 4 Oil cooler 1 5 O ring 1 6 Oil cooler inlet hose 1 7 Wat...

Page 351: ...OOLER 6 6 Removing the oil cooler Order Job Parts to remove Q ty Remarks 8 Water jacket joint 1 9 O ring 1 10 Water pump outlet pipe 1 11 O ring 1 12 O ring 1 For installation reverse the removal proce dure ...

Page 352: ...r union bolt and apply lithium soap based grease to the O ring Make sure the O ring is positioned properly Make sure the projection a on the oil cooler touches the projection b on the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING TH...

Page 353: ...age 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 12 1 Coolant reservoir cover 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir cap 1 5 Coolant reservoir tank 1 6 Thermostat outlet hose 1 7 Thermostat housing cover 1 8 O ring 1 9 Thermostat 1 10 Thermostat housing 1 11 Thermostat inlet hose 1 ...

Page 354: ...hermostat Order Job Parts to remove Q ty Remarks 12 Thermostat bypass hose 2 1 13 Water pump bypass hose 1 14 Joint 1 15 Thermostat bypass hose 1 1 16 Engine outlet pipe 1 17 O ring 1 For installation reverse the removal proce dure ...

Page 355: ...ermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat housing cover 1 Thermostat housing 2 Cracks damage Replace 3 Check Thermostat hoses Thermostat bypass hoses Water pump bypass hose Engine outlet pipe Cracks damage Replace EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat ...

Page 356: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 357: ...es Q ty Remarks Oil water pump assembly Refer to OIL PUMP on page 5 51 Oil pump rotor Refer to OIL PUMP on page 5 51 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5 Water pump seal 1 6 Oil seal 1 7 O ring 1 For installation reverse the removal proce dure ...

Page 358: ...KING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the oil water pump assembly EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 TIP Before installing the oil seal apply tap water or coolant onto its out surface Install the oil seal with a socket that matches its outs...

Page 359: ...and 4 ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 2 Water pump housing 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down New New Impeller shaft tilt limit 0 15 mm 0 006 in 1 S...

Page 360: ...WATER PUMP 6 15 ...

Page 361: ... FILTER CASE SEAL 7 9 CHECKING THE INTAKE FUNNEL 7 9 INSTALLING THE INTAKE FUNNEL AND LOWER AIR FILTER CASE 7 9 CHECKING THE INTAKE FUNNEL OPERATION 7 9 INSTALLING THE SECONDARY INJECTORS 7 10 INSTALLING THE UPPER AIR FILTER CASE 7 10 INSTALLING THE FUEL HOSE PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE 7 11 THROTTLE BODIES 7 12 CHECKING THE PRIMARY INJECTORS BEFORE REMOVING 7 15 ...

Page 362: ...collar washer 2 2 2 4 Fuel tank breather hose 1 Disconnect 5 Fuel tank overflow hose 1 Disconnect 6 Fuel pump coupler 1 Disconnect 7 Fuel sender coupler 1 Disconnect 8 Fuel hose connector cover 1 9 Fuel hose fuel tank side 1 Disconnect 10 Cover bolt washer 1 1 1 11 Fuel tank 1 12 Fuel tank breather hose fuel tank to hose joint 1 13 Fuel tank overflow hose fuel tank to hose joint 1 14 Hose joint 1 ...

Page 363: ...FUEL TANK 7 2 Removing the fuel tank and fuel pump Order Job Parts to remove Q ty Remarks 15 Fuel pump bracket 1 16 Fuel pump 1 17 Fuel pump gasket 1 For installation reverse the removal proce dure ...

Page 364: ...ly disconnect the hose with tools TIP To remove the fuel hose from the fuel pump press the two buttons 1 on the sides of the connector and then remove the hose Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fue...

Page 365: ...stalling the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard Fuel hose connector cover TIP Attach the fuel hose connector cover 1 to the fuel hose connector 2 from the bottom...

Page 366: ...coupler 1 Disconnect 3 Fuel hose secondary injector fuel rail side 1 Disconnect 4 Upper air filter case 1 5 Sub wire harness 1 6 Secondary injector holder 1 7 Secondary injector 4 8 Fuel rail 2 9 Secondary injector joint 1 10 Air filter element 1 11 Intake funnel joint bolt 6 Loosen 12 Intake funnel servo motor coupler 1 Disconnect 13 Air induction system hose air filter case to air cut off valve ...

Page 367: ...he air filter case and secondary injectors Order Job Parts to remove Q ty Remarks 15 Intake funnel servo motor rod assembly 1 16 Intake funnel assembly 1 17 Intake funnel servo motor 1 For installation reverse the removal proce dure ...

Page 368: ...e arrow shown press the two but tons 2 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed EAS14B1106 REMOVING THE SECONDARY INJECTORS WARNING EWA14B1027 Check the injectors in a well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the...

Page 369: ...air filter case duct EAS14B1077 REMOVING THE INTAKE FUNNEL ASSEM BLY 1 Remove Intake funnel servo motor rod assembly Intake funnel assembly Intake funnel servo motor ECA14B1045 Do not disassemble the intake funnel assembly a Keep the two tabs a pushed in the direc tion shown in the illustration and separate the intake funnel assembly from lower air filter case ECA14B1038 Do not remove the bolts 1 ...

Page 370: ... from the upper position to the seating position by its own weight EAS14B1067 INSTALLING THE INTAKE FUNNEL AND LOWER AIR FILTER CASE 1 Install Intake funnel servo motor Intake funnel servo motor rod assembly Lower air filter case Intake funnel assembly Intake funnel joint bolts EAS14B1080 CHECKING THE INTAKE FUNNEL OPERA TION 1 Check Intake funnel servo motor operation a Activate the diagnostic mo...

Page 371: ...pecified torque 1 Install a new seal onto the end of each injector 2 Install the injectors 1 to the fuel rails 2 3 Install the secondary injector joint 3 mak ing sure to install them in the correct direc tion 4 Tighten the fuel rail screws 1 5 Install Upper air filter case seal 1 Secondary injector assembly seal 2 TIP The matching adhesion portion of the seal should be positioned within a range of...

Page 372: ...se make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the sec ondary injector joint until a distinct click is heard To install the fuel hose onto the secondary injector joint slide the fuel hose connector cover 1 on the end of the ho...

Page 373: ...sition sensor coupler 1 Disconnect 3 Sub wire harness coupler 2 Disconnect 4 Intake air pressure sensor coupler 1 Disconnect Coupler marked B 5 Throttle servo motor coupler 1 Disconnect 6 Coolant temperature sensor coupler 1 Disconnect 7 Fuel hose 2 8 Throttle cable accelerator cable 1 Disconnect 9 Throttle cable decelerator cable 1 Disconnect 10 Throttle body joint clamp 4 Loosen 11 Throttle body...

Page 374: ...3 Removing the throttle body assembly Order Job Parts to remove Q ty Remarks 14 Crankshaft position sensor coupler 1 Disconnect 15 Heat protector 1 16 Throttle body joint 2 For installation reverse the removal proce dure ...

Page 375: ...nect 3 Primary injector coupler 3 1 Disconnect 4 Primary injector coupler 4 1 Disconnect 5 Sub wire harness 1 6 Intake air pressure sensor hose 5 7 Intake air pressure sensor 1 8 Fuel rail 2 9 Primary injector joint 1 10 Primary injector 4 11 Throttle position sensor 1 12 Accelerator position sensor 1 13 Throttle bodies 1 For installation reverse the removal proce dure ...

Page 376: ... Air filter case Throttle bodies 2 Remove Sub wire harness Primary injectors a Remove the fuel rail screws 1 as shown 3 Remove Fuel rails 1 Primary injector joint 2 EAS14B1110 CHECKING THE PRIMARY INJECTORS 1 Check Injectors Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 144 E...

Page 377: ...t surface with the air filter case side facing up b Install the caps 895 14169 00 onto the hose fittings a c Push the lever in the direction shown in the illustration to hold the throttle valves in the open position WARNING EWA14B1022 When cleaning the throttle bodies be care ful not to injure yourself on the throttle valves or other components of the throttle bodies ECA14B1028 Do not open the thr...

Page 378: ...r pinch the O rings when installing the injectors When installing the injector install it at the same position as the removed cylin der If an injector is subject to strong shocks or excessive force replace it If installing the original fuel rails and bolts remove the white paint marks using a cleaning solvent Otherwise paint chips on the bolt seats could prevent the bolts from being tightened to t...

Page 379: ...ssure a Remove the fuel tank bolt and holdup the fuel tank b Disconnect the fuel hose 1 from the fuel tank WARNING EWA14B1001 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses ECA14B1003 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools c Connect the ...

Page 380: ... selected g Adjust the position of the throttle position sensor angle so that 12 21 can appear in the meter h After adjusting the throttle position sensor angle tighten the throttle position sensor screws 1 EAS14B1074 ADJUSTING THE ACCELERATOR POSI TION SENSOR WARNING EWA14B1024 Handle the accelerator position sensor with special care Never subject the accelerator position sensor to strong shocks ...

Page 381: ... 14 is selected g Adjust the position of the accelerator posi tion sensor angle so that 12 22 can appear in the meter h After adjusting the accelerator position sen sor angle tighten the accelerator position sensor screws 1 Accelerator position sensor screw 3 5 Nm 0 35 m kgf 2 5 ft lbf ...

Page 382: ...AIR INDUCTION SYSTEM 7 21 EAS27040 AIR INDUCTION SYSTEM ...

Page 383: ...AIR INDUCTION SYSTEM 7 22 1 Lower air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 384: ...r case duct 2 2 Atmospheric pressure sensor coupler 1 Disconnect 3 Air filter case duct 1 4 Atmospheric pressure sensor hose 1 Disconnect 5 Atmospheric pressure sensor 1 6 Air induction system solenoid coupler 1 Disconnect 7 Air induction system hose air filter case to air cut off valve 1 8 Air induction system hose air cut off valve to reed valve cover 2 9 Air cut off valve 1 For installation rev...

Page 385: ...IR INDUCTION SYSTEM 7 24 Removing the reed valves Order Job Parts to remove Q ty Remarks 1 Reed valve cover 2 2 Reed valve assembly 2 3 Reed valve plate 4 For installation reverse the removal proce dure ...

Page 386: ...the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified v...

Page 387: ...EM 1 Install Reed valves Reed valve stoppers Reed valve base 2 Install Reed valve plate TIP Align the projection a on the cylinder head cover 1 with the hole b in the reed valve plate Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 3 Install Reed valve cover A Exhaust side Reed valve cover bolt air induc tion system 10 Nm 1 0 m ...

Page 388: ...AIR INDUCTION SYSTEM 7 27 ...

Page 389: ...ING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 37 DIAGNOSTIC MODE 8 38 TROUBLESHOOTING DETAILS 8 45 FUEL PUMP SYSTEM 8 103 CIRCUIT DIAGRAM 8 103 TROUBLESHOOTING 8 105 IMMOBILIZER SYSTEM 8 107 CIRCUIT DIAGR...

Page 390: ...5 CHECKING THE HORN 8 135 CHECKING THE OIL LEVEL SWITCH 8 136 CHECKING THE FUEL SENDER 8 136 CHECKING THE SPEED SENSOR 8 137 CHECKING THE RADIATOR FAN MOTOR 8 137 CHECKING THE COOLANT TEMPERATURE SENSOR 8 138 CHECKING THE THROTTLE POSITION SENSOR 8 138 CHECKING THE ACCELERATOR POSITION SENSOR 8 139 CHECKING THE THROTTLE SERVO MOTOR 8 139 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 140 CHECKING TH...

Page 391: ......

Page 392: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 393: ...engine control unit 22 Ignition coil 1 23 Ignition coil 2 24 Ignition coil 3 25 Ignition coil 4 26 Spark plug 41 Crankshaft position sensor 45 Cylinder identification sensor 46 Lean angle sensor 64 Right handlebar switch 67 Engine stop switch 69 Gear position sensor 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 394: ...w to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the side stand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed an...

Page 395: ...tery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Gear position sensor 12 Battery negative lead 13 Engine ground ...

Page 396: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 132 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI T...

Page 397: ...he right handlebar switch 10 Check the gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR on page 8 143 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 131 Replace the relay unit 13 Check the lean angle sensor Refer to ...

Page 398: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 399: ...lay 11 Starter motor 12 Relay unit 13 Starting circuit cut off relay 15 Sidestand switch 64 Right handlebar switch 67 Engine stop switch 68 Start switch 69 Gear position sensor 71 Left handlebar switch 76 Clutch switch 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 400: ...ral position The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above con...

Page 401: ...ER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Gear position sensor 11 Start switch 12 Starter relay 13 Starter motor 14 Battery negative lead 15 Engine ground ...

Page 402: ...echarge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 134 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 48 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHEC...

Page 403: ...E GEAR POSITION SENSOR on page 8 143 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the right handlebar switch 14 Check the entire st...

Page 404: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 405: ...CHARGING SYSTEM 8 14 2 AC magneto 3 Rectifier regulator 4 Main fuse 8 Battery 101 Engine ground 102 Battery negative lead ...

Page 406: ...o CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 134 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 135 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DIA...

Page 407: ...CHARGING SYSTEM 8 16 ...

Page 408: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 409: ...bly 59 High beam indicator light 62 Meter light 71 Left handlebar switch 73 Pass switch 74 Dimmer switch 83 Headlight 84 Auxiliary light 85 Ground cord headlight 86 License plate light 88 Tail brake light 89 Headlight relay 95 Headlight fuse 97 Turn signal light fuse 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 410: ...n turn sig nal light and fuel injection system Refer to CHECKING THE FUSES on page 8 125 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch immobilizer nut 5 Check the dimmer switch Refer to CHECKING TH...

Page 411: ...LIGHTING SYSTEM 8 20 NG OK 8 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting system s wiring Replace the ECU or meter assembly ...

Page 412: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 413: ...olant temperature warning light 60 Left turn signal indicator light 61 Right turn signal indicator light 63 Oil level switch 64 Right handlebar switch 66 Front brake light switch 69 Gear position sensor 70 Turn signal hazard relay 71 Left handlebar switch 72 Hazard switch 75 Horn switch 77 Turn signal switch 78 Horn 79 Front left turn signal light 80 Front right turn signal light 81 Rear left turn...

Page 414: ...n system Refer to CHECKING THE FUSES on page 8 125 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch immobilizer unit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 ...

Page 415: ... 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 124 Replace the tur...

Page 416: ...nect or repair the signal ing system s wiring Replace the meter assembly 1 Check the gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR on page 8 143 Replace the gear position sensor 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 131 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect...

Page 417: ...ge 8 136 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 138 Replace the coolant temperature sen sor 2 Check the entire signaling system s wiring Refe...

Page 418: ...al ing system s wiring Replace the ECU or meter assembly 1 Check that the shift timing indicator light is set to come on and that the brightness level of the light is adjusted properly Refer to FEATURES on page 1 2 Replace the meter assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the meter...

Page 419: ...SIGNALING SYSTEM 8 28 ...

Page 420: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 421: ...stem fuse 21 ECU engine control unit 42 Coolant temperature sensor 90 Radiator fan motor relay 91 Right radiator fan motor fuse 92 Left radiator fan motor fuse 93 Right radiator fan motor 94 Left radiator fan motor 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 422: ... battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 137 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 129 Replace the radiator fan motor relay 6 Check the coolant temperature sensor Refe...

Page 423: ...COOLING SYSTEM 8 32 ...

Page 424: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 425: ...econdary injector 2 33 Secondary injector 3 34 Secondary injector 4 35 Air induction system solenoid 36 Intake funnel servo motor 37 Throttle servo motor 38 Steering damper solenoid 39 Speed sensor 40 Intake air temperature sensor 41 Crankshaft position sensor 42 Coolant temperature sensor 43 Intake air pressure sensor 44 Atmospheric pressure sensor 45 Cylinder identification sensor 46 Lean angle ...

Page 426: ...n LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main swi...

Page 427: ...g light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating depending on the condi...

Page 428: ... on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine Fault code No No fault code No Check and repair Refer to TROU...

Page 429: ...opwatch LCD 6 Set the engine stop switch to 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET switches TIP To decrease the selected diagnostic code number press the RESET switch 1 Press the RESET switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELE...

Page 430: ...temperature closer to air temperature When engine is hot Air tem perature approx 20 C 68 F Compare the actually mea sured intake air temperature with the meter display value D 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the meter display val...

Page 431: ...0 Sidestand switch Set on off the sidestand switch with the transmis sion in gear Stand retracted ON Stand extended OFF D 21 Gear position switch and clutch switch Shift the transmission Gear is in neutral ON Gear is in other than neu tral and not operating clutch OFF Gear is in other than neu tral operating clutch and using sidestand OFF Gear is in other than neu tral operating clutch and storing...

Page 432: ...alfunction that have occurred since the his tory was last erased For example if there have been three malfunctions 03 is displayed To erase the history set the engine stop switch from to D 63 Malfunction code reinstate ment for fault code No 24 40 only No malfunction code 00 Malfunction code exists Fault code 24 40 If more than one code number is detected the dis play alternates every two seconds ...

Page 433: ...ou ble warning light Check the spark five times Connect an ignition checker D 34 Intake funnel servo motor Actuates the intake funnels up position down position for each 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the intake funnel servo motor D 36 Primary injector 1 Actuates the primary injector 1 five times at one second intervals Illuminates the engine t...

Page 434: ...rou ble warning light Check the operating sound of the secondary injector 4 five times D 47 Steering damper solenoid Set the engine stop switch to ON Steering damper sole noid is ON Set the engine stop switch to OFF Steering damper sole noid is OFF Illuminates the engine trou ble warning light when the engine stop switch is ON Check the operating of the steering damper D 48 Air induction system so...

Page 435: ...the engine trou ble warning light Check the operating sound of the radiator fan motor relay five times D 52 Headlight relay Actuates the headlight relay for five cycles of five seconds ON 2 seconds OFF 3 sec onds Illuminates the engine trou ble warning light Check the operating sound of the headlight relay five times Diag nostic code No Item Actuation Checking method ...

Page 436: ...coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or l...

Page 437: ...intenance job Sensor inspection proce dure 1 Connection of crankshaft position sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next ...

Page 438: ...t code indicated Recovered Fault code indicated Check the next step 5 Crankshaft position sensor malfunction Sensor inspection procedure Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 133 Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 12 Symptom Normal signal...

Page 439: ...ck the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indica...

Page 440: ...or inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 141 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 13 Symptom Open or short circuit of intake air pressure sensor lead Fail safe action Engine startup Possible Ridi...

Page 441: ...r pressure sen sor hose is damaged discon nected clogged twisted or bent Repair or replace the sensor hose Starting the engine and oper ating it at idle Fully close the throttle and check the fault recovery 2 Intake air pressure sensor malfunction Check in the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m abov...

Page 442: ...ire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the ma...

Page 443: ...of power supply line 0 V Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 01 D 13 D 01 Meter display Throttle position sensor signal 1 12 21 fully closed position 97 106 fully opened position Checking method Check with throttle v...

Page 444: ... indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 01 D 13 D 01 Meter display Throttle position sensor signal 1 12 21 fully closed posi...

Page 445: ...oupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Check the next step 3 Connection ...

Page 446: ...ded No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Symptom Open or short circuit of ECU input line Blue Yellow lead Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitor ing code No D 20 Meter display Sidestand switch ON stand retracted OFF stand extended Checking method Set on off the sidestan...

Page 447: ...re the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Intake air pressure sensor malfunction Check in the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 3000 m above sea...

Page 448: ...o fault code indicated Recovered Fault code indicated Check the next step 3 ECU malfunction Replace the ECU Fault code No 20 Symptom When the main switch is ON there is a big difference in voltage value of the intake air pressure sensor and atmospheric pressure sensor Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No D 03 D 02 D 03 Meter display Displays the i...

Page 449: ...in for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of primary injec tor sub wire harness coupler Check the connection of the coupler is secure Remove the coupler and check each pin for...

Page 450: ...e sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check t...

Page 451: ...tion procedure Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENSOR on page 8 142 During cold starting A tem perature close to the ambient temperature is indicated Indication is incorrect Replace the intake air tem perature sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction...

Page 452: ... securely or replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire h...

Page 453: ...to CHECKING THE ATMOSPHERIC PRES SURE SENSOR on page 8 140 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 23 Symptom Open or short circuit of atmospheric pressure sensor lead Fail safe action Engine startup Possible Riding Possible Diagnostic moni...

Page 454: ... code indicated Recovered Fault code indicated Check the next step 3 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Either start and warm up the engine and then racing it or reset it with diagnostic code 63 No fault code indi...

Page 455: ... job Sensor inspection proce dure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch is first turned OFF No fault code indicated Recovered Fault code indicated Check the next step 2 Sensor installation status Check for a loose mounting pinched mounting or sensor mounting direction up...

Page 456: ...on coil five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the spark five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking P...

Page 457: ...ircuit Replace the wire harness Orange Orange Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately ...

Page 458: ...k five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approximately 5 sec...

Page 459: ... short circuit Replace the wire harness Gray Red Gray Red Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the connection of the coupler is secure Make sure that the mounting position is correct Start and idle the engine for approximately 5 ...

Page 460: ...park five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds...

Page 461: ... Replace the wire harness Orange Green Orange Green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approxim...

Page 462: ...k five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approximately 5 sec...

Page 463: ...hort circuit Replace the wire harness Gray Green Gray Green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the connection of the coupler is secure Make sure that the mounting position is correct Start and idle the engine for approximately ...

Page 464: ... Code No 33 If not ignited replace the defective ECU Fault code No 36 Symptom Ignition coil 4 primary lead malfunction Fail safe action Engine startup Possible depending on the number of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 33 Meter display Actuates the cylinder 4 ignition coil five times at one second inter vals Illuminates...

Page 465: ...r 3 five times D 39 Actuator oper ation Actuates the primary injector 4 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 4 five times Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Locate the malfunction Check in the diagnostic mode Code No 36 37 38 39 Refer ...

Page 466: ...ngine startup Possible depending on the number of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 36 D 37 D 38 D 39 D 36 Actuator oper ation Actuates the primary injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 1 five times D 37 ...

Page 467: ...r ing code No D 36 D 37 D 38 D 39 D 36 Actuator oper ation Actuates the primary injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 1 five times D 37 Actuator oper ation Actuates the primary injector 2 five times at one second intervals Illuminates the engine trouble warning light Checking meth...

Page 468: ...es at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 3 five times D 43 Actuator oper ation Actuates the secondary injector 4 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 4 five times Item components and proba...

Page 469: ... failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary i...

Page 470: ...r ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary injector 2 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the seconda...

Page 471: ...stic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary injector 2 five times at one second inter vals Illuminates the engine trouble warning ...

Page 472: ...en rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the harness Rotate the main switch to the O...

Page 473: ... Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 41 Symptom Open or short circuit of lean angle sensor lead Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitor ing code No D 08 Meter display Lean angle sensor 0 4 1 4 upright 3 7 4 4 overturned Checking method Remove the lean angle sensor and incline more than 45 degrees Item comp...

Page 474: ...N neutral OFF in gear Checking method Shift the transmission and clutch lever C Fail safe action Engine startup Possible Riding Possible Diagnostic monitoring code No D 21 Clutch switch Meter display ON Gear is in other than neutral operating clutch and stor ing sidestand OFF Gear is in other than neutral operating clutch and using sidestand Checking method Shift the transmission clutch lever and ...

Page 475: ...or repair replace the wire harness Start the engine and check the connection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circuit Replace the wire harness Black Blue Black Blue Blue Blue White Yellow White Yellow...

Page 476: ...nect or repair the coupler Start the engine and check the secure connection of the coupler Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of leads between gear position sensor and relay unit coupler Open short circuit Replace the wire harness Sky blue Sky blue Start the e...

Page 477: ... code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of clutch switch coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Recon nect or repair the coupler Start the engine and check the secure connection of the coupler Ride the vehicle at a low speed approx 20 30 ...

Page 478: ...U Fault code No 43 Symptom Incorrect voltage supplied to the fuel injector and fuel pump Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No D 50 Meter display Approximately 12 0 Checking method Set the engine stop switch to and then compare with the actu ally measured battery voltage If the battery voltage is lower per form recharging Item components and probab...

Page 479: ...indicated Recovered Fault code indicated Check the next step 4 Fuel injection system relay malfunction Check in the diagnostic mode Code No 50 No operation sound of fuel injection system relay is heard Replace the relay unit Start and idle the engine for approximately 30 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 ECU ma...

Page 480: ...indication Check number 2 02 indication Check number 3 03 indication Check number 4 04 indication Check number 5 2 01 is indicated in Diagnostic mode Code No 60 EEP ROM data error for adjustment of CO concentra tion of cylinder 1 Change the CO concentra tion of cylinder 1 and rewrite in EEP ROM After this adjustment is made the memory is not recovered when the main switch is turned OFF and ON agai...

Page 481: ...h is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 44 Symptom An error is detected while reading or writing on EEP ROM Fail safe action Engine startup Under certain conditions Riding Under certain conditio...

Page 482: ...main switch Red Red Between the main switch and ignition fuse Brown Blue Brown Blue Between the ignition fuse and ECU Red White Red White Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Battery malfunction Check the battery voltage Refer to CHECKING AND CHARGING THE BATTERY on pa...

Page 483: ...open D 15 Meter display Accelerator position sensor signal 2 10 24 fully closed position 95 109 fully opened position Checking method Check with throttle grip fully closed Check with throttle grip fully open Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of accelerator position sensor coupler Check the connection of the coupler is secure Remov...

Page 484: ...ult code indicated Recovered Fault code indicated Check the next step Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully op...

Page 485: ...n of power supply line 0 V Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully opened position Checking method Check with th...

Page 486: ...lt code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 full...

Page 487: ...ing Poor connection Connect it securely or replace the har ness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Check the ETV Electronic Throttle Valve fuse Abnormality Replace the ETV Electronic Throttle Valve fuse Place the main switch to the ON position and check the fault code indication N...

Page 488: ...ler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the...

Page 489: ...ode indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 70 Symptom Engine has been left idling The ECU automatically stops the engine after 20 minutes if it is left idling Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No Meter display Checking method Item components and probable...

Page 490: ...Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harne...

Page 491: ...arness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short cir...

Page 492: ...of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or ...

Page 493: ...ction of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Op...

Page 494: ...FUEL PUMP SYSTEM 8 103 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 495: ...ch 4 Main fuse 8 Battery 9 Fuel injection system fuse 12 Relay unit 14 Fuel pump relay 16 Fuel pump 21 ECU engine control unit 64 Right handlebar switch 67 Engine stop switch 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 496: ...2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Ref...

Page 497: ...FUEL PUMP SYSTEM 8 106 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 103 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 498: ...IMMOBILIZER SYSTEM 8 107 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 499: ... fuse 5 Backup fuse 6 Immobilizer unit 8 Battery 9 Fuel injection system fuse 21 ECU engine control unit 47 Meter assembly 48 Immobilizer system indicator light 54 Multi function meter 100 Ignition fuse 101 Engine ground 102 Battery negative lead ...

Page 500: ...egistered during production therefore re registering at purchase is not neces sary ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immob...

Page 501: ...f the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator ligh...

Page 502: ...tch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 seconds insert t...

Page 503: ...b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registe...

Page 504: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 125 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 107 Properly connect or repair the immobi lizer system wiring Check the c...

Page 505: ... con secutive attempts 2 Signal received from unregistered stan dard key 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected com munication harne...

Page 506: ...55 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Undefinition code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobilizer unit 3 Replace the ECU Fault code Part Symptom Cause Action a Light on b Light of...

Page 507: ...IMMOBILIZER SYSTEM 8 116 ...

Page 508: ...ELECTRICAL COMPONENTS 8 117 EAS27972 ELECTRICAL COMPONENTS ...

Page 509: ...ch switch 5 Ignition coil 6 Battery 7 Fuse box 8 Main fuse 9 Fuel injection system fuse 10 Starter relay 11 Rear brake light switch 12 Gear position sensor 13 Sidestand switch 14 O2 sensor 15 Speed sensor 16 Oil level switch 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Steering damper ...

Page 510: ...ELECTRICAL COMPONENTS 8 119 ...

Page 511: ...r 5 Intake air pressure sensor 6 Intake funnel servo motor 7 Fuel pump 8 Relay unit 9 Lean angle sensor 10 Coolant temperature sensor 11 Crankshaft position sensor 12 Throttle servo motor 13 Throttle position sensor 14 Accelerator position sensor 15 Radiator fan motor relay 16 ECU engine control unit 17 Cylinder identification sensor ...

Page 512: ...ELECTRICAL COMPONENTS 8 121 EAS27980 CHECKING THE SWITCHES ...

Page 513: ...utch switch 3 Main switch 4 Dimmer switch 5 Pass switch 6 Turn signal switch 7 Hazard switch 8 Sidestand switch 9 Gear position sensor 10 Oil level switch 11 Front brake light switch 12 Engine stop switch 13 Start switch 14 Rear brake light switch ...

Page 514: ...and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a give...

Page 515: ...ight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb...

Page 516: ...ain check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS28030 CHECKING AND CHAR...

Page 517: ...l will drop considerably Therefore take special care when charging the bat tery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider seat Battery cover Refer ...

Page 518: ...ll contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illus...

Page 519: ...oltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on the battery This type o...

Page 520: ...n Out of specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery ter...

Page 521: ...f specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard 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 ha...

Page 522: ...tester probe Black Yellow 2 No continuity Positive tester probe Black Yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue Yellow 3 No continuity Positive tester probe Blue Yellow 3 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Sky blue White 4 No continuity Positive tester probe Sky bl...

Page 523: ...e 2 Check Secondary coil resistance Out of specification Replace a Connect the pocket tester Ω 1 k to the ignition coil as shown b Measure the secondary coil resistance 3 Check Ignition spark gap Out of specification Replace a Connect the ignition checker 1 as shown Primary coil resistance 0 85 1 15 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red Black 1 Negat...

Page 524: ... LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the battery box 2 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect the test harness lean angle sen sor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resistance 248 372 Ω at 20 C 68 F Pock...

Page 525: ...ise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the sta tor coil coupler a...

Page 526: ... 1 b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the rectifier regulator output volt age EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn leads from the horn terminals Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester...

Page 527: ... harness 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance Out of specification Replace a Connect the pocket tester Ω 1 to the fuel sender terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Horn terminal 1 Negative tester probe Horn terminal 2 Oil level switch Maximum level position resis tance 484 536 Ω Minimum l...

Page 528: ... from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Green White 1 Negative tester probe Black 2 Output voltage reading cycle 0 6 V...

Page 529: ...own b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Slowly heat the coolant then let it cool down to the specified temperature e Measure the coolant temperature sensor resistance EAS14B1086 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position s...

Page 530: ...r maximum resistance 3 Install Accelerator position sensor TIP When installing the accelerator position sen sor adjust its angle properly Refer to ADJUSTING THE ACCELERATOR POSI TION SENSOR on page 7 19 EAS14B1061 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter case Refer to AIR FILTER CASE on page 7 5 2 Check Throttle valve operation Throttle valves do not fully close Replace the throttle b...

Page 531: ...ation Replace a Connect the test harness S pressure sen sor 3P 1 to the atmospheric pressure sensor and wire harness as shown ECA14B1035 Pay attention to the installing direction of the test harness S pressure sensor 3P coupler a b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P A Check that the throttle valves 2 open B Check that the throttle valves 2 fully close S...

Page 532: ...age reading should cycle from 0 8 V to 4 8 V to 0 8 V to 4 8 V EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sen sor 3P 1 to the intake air pressure sen sor and wire harness as shown ECA14B1035 Pay attention to the installing direction of the test harness S pressure sensor 3P cou...

Page 533: ...r temperature sensor 1 in a container filled with water 2 TIP Make sure that the intake air temperature sen sor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS14B1020 CHECKING THE STEERING DAMPER SOLENOID 1 Remov...

Page 534: ...12 Analog pocket tester YU 03112 C Positive tester probe Black 1 Negative tester probe Black 2 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Result Neutral position Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a 1st position Continuity Positive tester probe White 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe...

Page 535: ...e Out of specification Replace the fuel injector a Disconnect the fuel injector lead coupler from wire harness b Connect the pocket tester Ω 1 to the fuel injector coupler c Measure the fuel injector resistance Fuel injector resistance Primary injector Secondary injector 12 0 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative...

Page 536: ...ELECTRICAL COMPONENTS 8 145 ...

Page 537: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 538: ...Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition ...

Page 539: ...t drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28570 FAULT...

Page 540: ...amaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or ...

Page 541: ...ctifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty m...

Page 542: ...ht 63 Oil level switch 64 Right handlebar switch 65 D Mode switch 66 Front brake light switch 67 Engine stop switch 68 Start switch 69 Gear position sensor 70 Turn signal hazard relay 71 Left handlebar switch 72 Hazard switch 73 Pass switch 74 Dimmer switch 75 Horn switch 76 Clutch switch 77 Turn signal switch 78 Horn 79 Front left turn signal light 80 Front right turn signal light 81 Rear left tu...

Page 543: ......

Page 544: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 545: ...WIRING DIAGRAM YZF R1 Y SCHEMA DE CABLAGE YZF R1 Y SCHALTPLAN YZF R1 Y SCHEMA ELETTRICO YZF R1 Y DIAGRAMA DE CONEXIONES DE YZF R1 Y ...

Page 546: ...WIRING DIAGRAM YZF R1 Y SCHEMA DE CABLAGE YZF R1 Y SCHALTPLAN YZF R1 Y SCHEMA ELETTRICO YZF R1 Y DIAGRAMA DE CONEXIONES DE YZF R1 Y ...

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