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Yamaha 2011 FZ8NA(C) Service Manual Download Page 470

TROUBLESHOOTING

9-1

EAS28451

TROUBLESHOOTING

EAS28460

GENERAL INFORMATION

TIP

The following guide for troubleshooting does 
not cover all the possible causes of trouble. It 
should be helpful, however, as a guide to basic 
troubleshooting. Refer to the relative proce-
dure in this manual for checks, adjustments, 
and replacement of parts.

EAS30410

STARTING FAILURES

Engine

1. Cylinder(s) and cylinder head(s)

• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve

2. Piston(s) and piston ring(s)

• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston

3. Air filter

• Improperly installed air filter
• Clogged air filter element

4. Crankcase and crankshaft

• Improperly assembled crankcase
• Seized crankshaft

Fuel system

1. Fuel tank

• Empty fuel tank
• Clogged fuel tank cap breather hole
• Clogged rollover valve (for California 

only)

• Clogged rollover valve hose (for Califor-

nia only)

• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose

2. 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 coil(s)

• Cracked or broken ignition coil body
• Broken or shorted primary or secondary 

coils

5. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Faulty cylinder identification sensor
• Broken pickup rotor straight key

6. Switches and wiring

• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections

7. Starting system

• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch

EAS30440

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder(s) and cylinder head(s)

• Incorrect valve clearance
• Damaged valve train components

2. Air filter

• Clogged air filter element

Summary of Contents for 2011 FZ8NA(C)

Page 1: ...SERVICE MANUAL FZ8NA C 2011 39P 28197 10 LIT 11616 24 07 ...

Page 2: ...Yamaha Motor Corporation U S A First edition November 2010 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 24 07 ...

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

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: ...ITION 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 LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

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: ...FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 BASIC SERVICE INFORMATION 1 9 QUICK FASTENERS 1 9 ELECTRICAL SYSTEM 1 9 SPECIAL TOOLS 1 14 ...

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

Page 11: ...nd cleaner exhaust 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 regula...

Page 12: ...e ECU Signals that are input from the throttle position sensor sub throttle position sensor crankshaft position sensor intake air pres sure sensor atmospheric pressure sensor intake air temperature sensor coolant temperature sen sor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position senso...

Page 13: ...r at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit ECA10031 Do not operate the engine in the tachome ter red zone Red zone 11500 r min and above Cl...

Page 14: ...SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level...

Page 15: ...rical circuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indicate an error code ECA11590 If the display indicates an error code the vehicle should be checked as soon as pos sible in order to avoid engine damage 1 Error code display ...

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

Page 17: ...ed grease Oil bearings liberally when installing if appropriate 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 opposit...

Page 18: ...nto the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastener insert the fastener into the part to be secured and tighten the screw a EAS30401 ELEC...

Page 19: ...ater ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA16770 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead If a tool or similar item contacts the vehicle while only the negative battery lead is connected ...

Page 20: ...ical system make sure that the battery voltage is at least 12 V ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler taking care not to loosen or dam age the leads ECA16640 For waterproof couplers never insert the tester probes directly into the coupler When performing any checks using a waterproof coupler use the ...

Page 21: ...tor securely and then disconnect the connector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect several times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling and assembling a cou pler pull on the leads to make sure that they are installed securely 4 Connect Lead C...

Page 22: ...th 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 most part stores Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 23: ...mbers or both may differ 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 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 60 Piston pin puller set 90890 01304 Piston pin puller YU...

Page 24: ...ing nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 20 4 60 Damper rod holder 90890 01423 Damping rod holder YM 01423 4 52 4 53 Oil filter wrench 90890 01426 YU 38411 3 24 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 51 4 56 Tool name Tool No Illustration Reference pages ...

Page 25: ... 4 56 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 54 4 56 Fork spring compressor 90890 01441 YM 01441 4 51 4 56 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 54 Pivot shaft wrench adapter 90890 01476 5 9 Tool name Tool No Illustration Reference pages ...

Page 26: ...3 5 1 Vacuum gauge 90890 03094 Vacuummate YU 44456 3 9 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 8 99 8 100 8 101 8 105 8 106 8 107 8 108 8 109 8 111 8 112 8 113 8 114 8 115 8 116 8 117 8 118 Oil pressure adapter H 90890 03139 3 25 Pressure gauge 90890 03153 YU 03153 3 25 7 5 7 10 Tool name Tool No Illustration Reference pages ...

Page 27: ...Feeler gauge set YU 26900 9 3 5 5 21 5 51 Test harness speed sensor 3P 90890 03208 YU 03208 8 113 8 117 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 109 Fuel injector pressure adapter 90890 03210 YU 03210 7 10 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 8 117 8 118 Test harness 3P sub throttle position sensor 90890 03214 YU 03214 7 13 Tool name Tool No Illustration Refer...

Page 28: ...ller 90890 04078 Water pump seal installer YM 33221 A 6 13 Universal clutch holder 90890 04086 YM 91042 5 49 5 53 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 6 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 25 5 31 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 27 Tool name Tool No Illustration Reference pages ...

Page 29: ...er ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 27 Extension 90890 04136 5 1 Camshaft wrench 90890 04162 YM 04162 5 14 5 17 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 109 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 19 5 34 5 67 Tool name Tool No Illustration Reference pages ...

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

Page 31: ...TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 41 ...

Page 32: ...th 2140 mm 84 3 in Overall width 770 mm 30 3 in Overall height 1065 mm 41 9 in Seat height 815 mm 32 1 in Wheelbase 1460 mm 57 5 in Ground clearance 140 mm 5 51 in Minimum turning radius 3000 mm 118 1 in Weight Curb weight 212 kg 467 lb USA 213 kg 470 lb California Maximum load 198 kg 437 lb USA 197 kg 434 lb California ...

Page 33: ...il quantity Total amount 3 80 L 4 02 US qt 3 34 Imp qt Without oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt With oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 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 housing clearance 0 ...

Page 34: ...stem Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 080 mm 0 0032 in Camshaft lobe dimensions Intake A 35 750 35 850 mm 1 4075 1 4114 in Limit 35 650 mm 1 4035 in Intake B 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1...

Page 35: ...n thickness D intake 0 50 0 90 mm 0 0197 0 0354 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1595 in Valve guide inside diamet...

Page 36: ...mm 0 067 in Spring tilt exhaust 2 5 1 7 mm 0 067 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 68 000 68 010 mm 2 6772 2 6776 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 Diameter D 67 975 67 990 mm 2 6762 2 6768 in Height H 11 5 mm 0 45 ...

Page 37: ... 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 55 20 56 60 mm 2 173 2 228 in Width B 298 75 300 65 mm 11 76 11 84 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 0 013 0 037 mm 0 0005 0 0015 in Limit 0 10 mm 0 0039 in Bearing color code 0 White 1 Blue 2 Black...

Page 38: ...ckness 5 76 5 89 mm 0 2268 0 2319 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 6 0 A Fuel pressure 324 0 kPa 3 24 kgf cm 47 0 psi Fuel injector Model quantity 297500 1720 4 Throttle position sensor Resistance 2 64 6 16 kΩ Output voltage at idle 0 63 0 73 V Sub throttle position sensor Resistance 3 7 kΩ Output voltage full clo...

Page 39: ...n Solenoid resistance 18 22 Ω at 20 C 68 F Idling condition Engine idling speed 1150 1250 r min CO 4 0 5 0 Intake vacuum 30 0 kPa 225 mmHg 8 9 inHg Water temperature 90 0 110 0 C 194 00 230 00 F Oil temperature 75 0 95 0 C 167 00 203 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 40: ...tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model BRIDGESTONE BT021R BB Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition 90 198 kg 198 437 lb USA 90 197 kg 198 434 lb California Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High...

Page 41: ...pe Angular bearing Center to lock angle left 33 0 Center to lock angle right 33 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil Front fork travel 130 0 mm 5 12 in Fork spring free length 286 1 mm 11 26 in Limit 280 4 mm 11 04 in Collar length 100 0 mm 3 94 in Installed length 278 6 mm 10 97 in Spring rate K1 8 82 N mm 0 90 kgf mm 50 36 lb in Spring stroke K1 0 0 ...

Page 42: ... 0 kgf cm 170 7 psi Spring preload adjusting positions Minimum 1 Standard 5 Maximum 9 Drive chain Type manufacturer 525V10 DAIDO Number of links 122 Drive chain slack 20 0 30 0 mm 0 79 1 18 in 15 link length limit 239 3 mm 9 42 in Shift pedal Installed shift rod length 304 1 306 1 mm 11 97 12 05 in ...

Page 43: ...ifier regulator output voltage 14 2 14 8 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate amperage 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 W 55 W 1 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal position light 12 V 21 0 W 5 W 2 Rear turn signal light 12 V ...

Page 44: ... 3 0 A Coil resistance 1 066 1 114 Ω at 20 C 68 F Turn signal relay Relay type Full transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Ω Minimum level position resistance 114 126 Ω Speed sensor Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8 V Coolant temperature sensor Resistance 2 45 kΩ at 20 C 68 F 290 354 Ω at 80 C 176 F Fuses Ma...

Page 45: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 46: ... 0 m kgf 7 2 ft lbf Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil pump bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Water pump cover bolt M6 5 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 Thermostat inlet pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Oil cooler bolt M20 1 63 Nm 6 3 m kgf 46 ft lbf Engine oil drain bolt M14 1 43 Nm 4 3 m kgf 31...

Page 47: ... m kgf 8 7 ft lbf Pickup rotor cover blind bolt M8 1 15 Nm 1 5 m kgf 11 ft lbf Oil filler cap M20 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Main gallery plug oil return M16 3 8 Nm 0 8 m kgf 5 8 ft lbf Main gallery plug M20 1 8 Nm 0 8 m kgf 5 8 ft lbf Oil return pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil return plug M12 2 32 Nm 3 2 m kgf 23 ft lbf AC magneto lead bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Stator...

Page 48: ...h the specified angle 56 61 Shift rod locknut front M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Shift rod locknut rear M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Left thread Shift rod joint bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Shift arm bolt M6 1 14 Nm 1 4 m kgf 10 ft lbf Neutral switch M10 1 17 Nm 1 7 m kgf 12 ft lbf Coolant temperature sensor M12 1 18 Nm 1 8 m kgf 13 ft lbf Cylinder identification sensor bolt M6 1 8 Nm ...

Page 49: ...TIGHTENING TORQUES 2 18 ...

Page 50: ...7 Nm 1 7 m kgf 12 ft lbf Left thread Grip end and handlebar bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Horn bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Lower headlight stay and lower bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Lower headlight stay and brake hose nut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Upper headlight stay and upper bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt M6 4 6 Nm 0 6 m kgf 4 3...

Page 51: ...lt M6 2 3 0 Nm 0 30 m kgf 2 2 ft lbf Seat lock assembly nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Mud guard assembly bolt M8 4 15 Nm 1 5 m kgf 11 ft lbf License plate light bolt M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Rear reflector nut M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Rear side reflector bracket and mud guard assembly M4 4 1 3 Nm 0 13 m kgf 0 94 ft lbf Rear side reflector nut M5 2 2 5 Nm 0 25 m kgf 1 8 ft lb...

Page 52: ...brake pad retaining bolt M10 1 17 Nm 1 7 m kgf 12 ft lbf Rear brake caliper screw plug M10 1 2 5 Nm 0 25 m kgf 1 8 ft lbf Rear wheel sprocket nut M10 6 80 Nm 8 0 m kgf 58 ft lbf Drive chain adjusting locknut M8 2 16 Nm 1 6 m kgf 12 ft lbf Rear brake hose union bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Sidestand nut M10 1 48 Nm 4 8 m kgf 35 ft lbf Sidestand bracket bolt M10 2 63 Nm 6 3 m kgf 46 ft lbf S...

Page 53: ...mp rotors inner and outer O ring oil nozzle O ring main gallery plug Damper crankcase left side Water or silicone fluid Idler gear and idler gear shaft Starter clutch assembly Starter clutch gear thrust surface Primary driven gear Pull rod Oil water pump assembly drive sprocket inner surface Oil water pump assembly drive sprocket collar and washer Transmission gears wheel and pinion Main axle and ...

Page 54: ...ON POINTS AND LUBRICANT TYPES 2 23 Left crankcase cover three 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 55: ... shaft Swingarm head pipe end bush and dust cover lips Oil seal relay arm connecting arm and rear shock absorber Sidestand pivoting point and metal to metal moving parts Sidestand switch contact point Sidestand hook and spring contact point Shift shaft joint rod moving parts Shift pedal pivoting parts Rear footrest ball and metal to metal moving parts Front wheel oil seal left and right Rear wheel...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 57: ...mp 3 Relief valve 4 Oil cooler 5 Oil filter 6 Main gallery 7 AC magneto drive gear shower 8 Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 AC magneto axle 13 Crankshaft 14 Piston cooler 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil delivery pipe 2 Oil level switch 3 Oil filter cartridge 4 Crankshaft ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 2 3 4 5 6 7 8 1 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Oil pipe 3 Drive axle ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Main gallery 5 Crankshaft ...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 69: ...COOLING SYSTEM DIAGRAMS 2 38 1 Thermostat 2 Water pump 3 Radiator 4 Radiator fan 5 Oil cooler ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 39 ...

Page 71: ...COOLING SYSTEM DIAGRAMS 2 40 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...

Page 72: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING Handlebar front view ...

Page 73: ...ter of the front fork The headlight side cover and front fork must not be pinched C The horn lead and lower bracket must not interfere with each other D Clamp the horn lead to the Lower headlight stay and face the head of the clamp to out side of the vehicle and the end of the clamp to the rear of the vehicle Cut off the excess end of the clamp leaving 2 4 mm 0 08 0 16 in E Insert the bullet termi...

Page 74: ...CABLE ROUTING 2 43 Handlebar right side view ...

Page 75: ... the throttle body F Clamp the coolant reservoir hose and radi ator inlet hose and face the head of the clamp to the inside of the vehicle and the end of the clamp to the top of the vehicle Be careful that the end of the clamp does not protrude out of the radiator upper cover G To the wire harness H Route the right radiator fan motor lead such that it is as taut as possible within the area shown i...

Page 76: ...CABLE ROUTING 2 45 Engine right side view ...

Page 77: ...uld be under the cable guide C Route the fuel tank breather hose and fuel tank drain hose through the opening of the rear brake light switch stay D The clamp position should be at the center of bending of the brake fluid reservoir hose as shown in the illustration E Route the fuel tank breather hose and fuel tank drain hose further inward of the vehi cle than the brake fluid reservoir F To the wir...

Page 78: ...CABLE ROUTING 2 47 Engine right side view For California only ...

Page 79: ...p position should be at the center of bending of the brake fluid reservoir hose as shown in the illustration C Route the fuel tank drain hose through the opening of the rear brake light switch stay D Pass the fuel tank drain hose through the cable guide The paint mark on the fuel tank drain hose should be under the cable guide E Inside of the vehicle F Front of the vehicle G Install the clamp faci...

Page 80: ...CABLE ROUTING 2 49 Handlebar left side view ...

Page 81: ...swaging metal further to the front of the vehicle than the clamp and face the clamp opening to outside of the vehicle D Clamp the clutch cable left radiator fan motor lead and water pump breather hose and face the head of the clamp to the top of the vehicle and the end of the clamp to the inside of the vehicle Use the position of the cylinder head cover shown in the illus tration as a guide to ins...

Page 82: ...CABLE ROUTING 2 51 Engine left side view ...

Page 83: ...er pump breather hose and water pump inlet pipe F More than 10 mm 0 39 in G Route the sidestand switch lead further to the front of the vehicle than the water pump breather hose and water pump inlet pipe H Route the oil level switch lead further to the front of the vehicle than the water pump breather hose and water pump inlet pipe I There should be no exposure of bare con ductors due to the misal...

Page 84: ...CABLE ROUTING 2 53 Rear frame left side view ...

Page 85: ...lead Face the head of the clamp to the inside of the vehicle and the end of the clamp down B Route the ground lead between the rear frame bracket and battery box The ground rivet on the wire harness stem side should not be caught with the rear frame bracket C Upper side of the vehicle D Inside of the vehicle E Clamp the AC magneto lead and rectifier regulator lead and then insert the clamp into th...

Page 86: ...CABLE ROUTING 2 55 Rear frame left side view For California only ...

Page 87: ... Starter motor lead 8 Rectifier regulator lead 9 AC magneto lead 10 Fuel tank drain hose 11 Rear brake light switch lead 12 Brake fluid reservoir hose 13 Coolant reservoir tank drain hose 14 Speed sensor lead A Install the waterproof coupler to the recti fier regulator bracket B Upper side of the vehicle C Inside of the vehicle D To the radiator ...

Page 88: ...CABLE ROUTING 2 57 Frame top view ...

Page 89: ...ght radiator fan motor lead using the position of the throttle body shown in the illustration as a guide Order insignificant Face the head of the clamp to the inside of the vehicle and the end of the clamp to the bottom of the vehicle E Clamp the left handlebar switch lead and main switch lead at the white tape marks Order insignificant Face the head of the clamp to the rear of the vehicle and the...

Page 90: ...CABLE ROUTING 2 59 Frame top view ...

Page 91: ...ght switch I Insert the wire harness wrapping clamp to the hole of the frame J Atmospheric opening K Insert the main fuse to the battery band Soapy water can be spread L Install the waterproof coupler to the recti fier regulator bracket M Route the battery positive lead from inside the vehicle to under the wire harness It should not be routed above the wire har ness N Route the main fuse lead so t...

Page 92: ...CABLE ROUTING 2 61 Frame top view For California only ...

Page 93: ...harness rectifier regulator lead starter motor lead battery negative lead and AC magneto lead Face the head of the clamp to the inside of the vehicle and the end of the clamp down C For the clamp position use the illustration as a guide D Clamp the canister purge hose facing the clamp opening to the top of the vehicle E When clamping route the wire harness and pickup coil lead further outward of t...

Page 94: ...CABLE ROUTING 2 63 Frame top view ...

Page 95: ...e lead F Route the license plate light lead and right turn signal light lead under the turn signal relay G Route the license plate light lead and rear right turn signal light lead between the ribs of the battery box H Route the license plate light lead and rear right turn signal light lead under the rubber cover I Route the tail brake light lead and rear left turn signal light lead under the rubbe...

Page 96: ...CABLE ROUTING 2 65 Fuel tank left and bottom view ...

Page 97: ...he fuel tank nipple and clamp E Fit the black double lock side to the engine side F Fuel pump side G Insert the connector until the click sound is heard and check that the connector does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings H After item G mentioned above is finished check that the fuel...

Page 98: ...CABLE ROUTING 2 67 Front brake rear brake ...

Page 99: ...all the brake hose pushing it against the lower headlight stay C A parallel line to the front brake master cyl inder ceiling surface D 30 40 E Center line F Install the brake pipe so that the white paint mark on the pipe faces to the front of the vehicle G Clamp the brake hose facing the clamp latch to the bottom of the vehicle H Insert the brake hose holder claw firmly into the swingarm I Install...

Page 100: ...CABLE ROUTING 2 69 Canister top view For California only ...

Page 101: ...hose 4 Rectifier regulator 5 Rear frame 6 Fuel tank drain hose 7 Canister purge hose 8 Frame 9 Cap 10 Waterproof coupler 11 Rectifier regulator bracket 12 Grommet A Install the cap to the nut aligning the outer groove of the cap with the edge of the nut B Soapy water may be applied during instal lation ...

Page 102: ...CABLE ROUTING 2 71 Canister left side view For California only ...

Page 103: ...The clip should not be run onto the spool E Install the fuel tank breather hose fuel tank to rollover valve with the yellow paint marks facing to the left of the vehicle F Install the fuel tank drain hose with the white paint marks facing to the left of the vehicle G Pass the fuel tank drain hose through the clamp The fuel tank drain hose between the fuel tank and clamp should not be bent H Clamp ...

Page 104: ...CABLE ROUTING 2 73 Canister right side view For California only ...

Page 105: ... C Insert the hose to the end of the bending part of the pipe D Install the canister purge hose with the yel low paint marks facing to the right of the vehicle E Install the fuel tank breather hose fuel tank to rollover valve to the rollover valve with the white paint marks facing to the top Insert the hose until it touches the rollover valve F Direct the knob of the clip to the top of the vehicle...

Page 106: ...CABLE ROUTING 2 75 ...

Page 107: ...R DISC BRAKE 3 14 CHECKING THE REAR BRAKE PADS 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 15 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION 3 18 ADJUSTING THE DRIVE CHAIN SLACK 3 18 LUBRICATING THE DRIVE CHAIN 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 20 LU...

Page 108: ...NG THE REAR BRAKE LIGHT SWITCH 3 28 CHECKING AND LUBRICATING THE CABLES 3 28 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 29 CHECKING AND CHARGING THE BATTERY 3 29 CHECKING THE FUSES 3 29 REPLACING THE HEADLIGHT BULB 3 29 ADJUSTING THE HEADLIGHT BEAM 3 31 ...

Page 109: ......

Page 110: ...ISSION CONTROL SYSTEM No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 ...

Page 111: ...ary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check bearing assemblies for looseness 10 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 500 mi 800 km and after washing the motorcycle riding in the rain or riding in wet areas 11 Steering bearings Check be...

Page 112: ...heck operation and for oil leakage Replace if necessary 21 Rear suspension link pivots Check operation Correct if necessary 22 Engine oil Change warm engine before draining 23 Engine oil filter cartridge Replace 24 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene glycol antifreeze coolant every 24 months Change 25 Front and rear brake switches Check operati...

Page 113: ... CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Radiator upper cover Radiator upper bolt Radiator lower bolt Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the...

Page 114: ... Throttle body assembly Refer to THROTTLE BODIES on page 7 6 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 11 3 Remove Pickup rotor cover 1 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft...

Page 115: ...g chain with a wire to retrieve it if it falls into the crankcase 6 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 TIP Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place Valve clearance me...

Page 116: ...er to the following table for the available valve pads Example Valve pad number 163 Rounded value 165 New valve pad number 165 f Install the new valve pad 1 and the valve lifter 2 TIP Lubricate the valve pad with molybdenum disulfide oil Lubricate the valve lifter Top side with molybdenum disulfide oil Lubricate the valve lifter Outer side with engine oil Install the valve lifter and the valve pad...

Page 117: ...STING THE ENGINE IDLING SPEED TIP Prior to adjusting the engine idling speed the throttle bodies synchronization should be adjusted properly the air filter element should be clean and the engine should have ade quate compression 1 Start the engine and let it warm up for sev eral minutes 2 Install Digital tachometer Use goods on the market 3 Check Engine idling speed Out of specification Adjust 4 A...

Page 118: ...system Breather hoses Vacuum hoses Canister purge hoses for California only Fast idle plunger outlet hose Fast idle plunger inlet hose Checking the throttle bodies synchroniza tion 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS...

Page 119: ...If the throttle bodies synchronization cannot adjusted by the bypass air screw clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Measure Engine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 3 Stop the engine and remove the measuring equipment 4 Install Synchro...

Page 120: ...ster purge hose 2 Fuel tank breather hose fuel tank to roll over valve 3 Fuel tank breather hose rollover valve to canister 4 Canister breather hose 5 Cracks damage Replace Rollover valve 6 Refer to CHECKING THE ROLLOVER VALVE for California only on page 7 4 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Right side cover Left side cover Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS39P130...

Page 121: ...ter element will also affect throttle bodies synchronization leading to poor engine performance and possible overheating TIP When installing the air filter element into the air filter case cover make sure that the sealing surfaces are aligned to prevent any air leaks 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH CAB...

Page 122: ...n the dry road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level WARNING EWA13090 Use on...

Page 123: ...01 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is oper ated the air must be removed by bleeding the brake system Air in the brake system will considerably reduce brake perfor mance resulting...

Page 124: ... page 4 31 EAS21350 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 master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hy...

Page 125: ...leed 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 13 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 brake hose holders 1 Check Brake hose 1 Cracks...

Page 126: ... The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Tire ai...

Page 127: ...nstall the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EAS39P1308 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 7 and CHECKING THE REAR WHEEL on page 4 14 EAS39P1309 CHECKING THE SWINGARM OPERATION 1 Check Swingarm opera...

Page 128: ...f the adjusting block should be 0 5 mm 0 02 in or less There should be no clearance between the adjusting block and adjusting bolt c Tighten the wheel axle nut to specification d Tighten the locknuts to specification EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained prop erly it will wear out quickly Therefore the drive cha...

Page 129: ...eering nut wrench Move the steering to the left and right a cou ple of times to check that it moves smoothly c Loosen the lower ring nut 6 completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and ch...

Page 130: ...djust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position c Tighten both locknuts d Make sure the installed shift rod length is within specification EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS39P1310 CHECKING THE SIDESTAND SWITCH Re...

Page 131: ...the rear suspension EAS39P1311 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to CHECKING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 63 EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Adjust th...

Page 132: ...t 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 or higher Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again TIP Before checki...

Page 133: ... Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several minutes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 23 Oil filter wrench 90890 01426 YU ...

Page 134: ... 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification Check 6 Install Oil gallery bolt ECA39P1301 Be careful not to tighten too much EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright Pressure gauge 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Oil pres...

Page 135: ...ter may be used 3 Start the engine 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 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water jacket joint inlet hose 8 W...

Page 136: ...ect Coolant reservoir hose 11 Install Coolant reservoir tank 12 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING EWA13040 If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away wit...

Page 137: ... page 8 93 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light s...

Page 138: ...il the specified throttle cable free play is obtained c Tighten the locknut 1 WARNING EWA39P1301 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 EAS21760 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 102 EAS21770 CHECKING T...

Page 139: ...ight bulb holder ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 8 Install Headlight bulb holder 9 Install Headlight bulb cover 10 Connect Hea...

Page 140: ... a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b Headlight bolt 7 Nm 0 7 m kgf 5 1 ft lbf Headlight side cover bolt 3 8 Nm 0 38 m kgf 2 8 ft lbf Headlight side panel bolt 8 Nm 0 8 m kgf 5 8 ft lbf Headlight top cover bolt 1 5 Nm 0 15 m kgf 1 1 ft lbf Direction a Headlight beam is raised Direction b Headlight bea...

Page 141: ... PADS 4 24 REMOVING THE FRONT BRAKE CALIPERS 4 25 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 25 CHECKING THE FRONT BRAKE CALIPERS 4 26 ASSEMBLING THE FRONT BRAKE CALIPERS 4 26 INSTALLING THE FRONT BRAKE CALIPERS 4 26 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 ...

Page 142: ...EAR SHOCK ABSORBER ASSEMBLY 4 62 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE CONNECTING ARM AND RELAY ARM 4 64 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM 4 66 REMOVING THE SWINGARM 4 67 CHECKING THE SWINGARM 4 67 INSTALLING THE SWINGARM 4 68 CH...

Page 143: ......

Page 144: ...eat and battery Order Job Parts to remove Q ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Tool kit 1 4 Battery negative lead 1 5 Battery positive lead 1 6 Main fuse 1 7 Battery band 1 8 Battery 1 9 Battery seat 1 For installation reverse the removal proce dure ...

Page 145: ...ly 1 5 Headlight sub wire harness coupler 1 Disconnect 6 Left turn signal position light lead connector 3 Disconnect 7 Right turn signal position light lead connector 3 Disconnect 8 Left headlight side cover 1 9 Right headlight side cover 1 10 Headlight sub wire harness 1 11 Meter coupler 1 Disconnect 12 Meter assembly 1 13 Meter bracket 1 14 Meter seat 1 For installation reverse the removal proce...

Page 146: ... cover 1 3 Tail brake light lead coupler 1 Disconnect 4 Upper tail cover 1 5 Tail brake light bracket 1 6 Tail brake light assembly 1 7 Left turn signal light lead coupler 1 Disconnect 8 Right turn signal light lead coupler 1 Disconnect 9 License plate light lead connector 2 Disconnect 10 Mud guard assembly 1 11 Lower tail cover 1 For installation reverse the removal proce dure ...

Page 147: ...IS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Air filter case cover 1 2 Air filter 1 3 Crankcase breather hose 1 Disconnect 4 Throttle body hose 2 Disconnect 5 Funnel 2 6 Air induction system hose 1 Disconnect 7 Air filter case 1 For installation reverse the removal proce dure 2 0 Nm 0 20 m kgf 1 5 ft Ibf T R ...

Page 148: ...e discs Order Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Front brake caliper 2 3 Reflector bracket 2 4 Reflector 2 5 Wheel axle pinch bolt 1 Loosen 6 Wheel axle 1 7 Collar 2 8 Front wheel 1 9 Front brake disc 2 For installation reverse the removal proce dure ...

Page 149: ...FRONT WHEEL 4 6 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 For assembly reverse the disassembly pro cedure ...

Page 150: ...nds 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 17 and CHECKING THE WHEELS on page 3 17 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 seal Damage wear Rep...

Page 151: ...itable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front whe...

Page 152: ...he lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the position...

Page 153: ...hard on the handlebar several times and check if the front fork rebounds smoothly TIP Check that wheel axle end a is flush with front folk surface b and then tighten the wheel axle pinch bolt If end a is not flush with sur face b align the ends manually or with a plastic hammer 6 Install Front brake caliper WARNING EWA13500 Make sure the brake hose is routed prop erly Recommended lubricant Lithium...

Page 154: ...y Remarks Rear brake caliper Refer to REAR BRAKE on page 4 31 1 Locknut 2 Loosen 2 Adjusting bolt 2 Loosen 3 Wheel axle nut 1 4 Washer 1 5 Wheel axle 1 6 Left adjusting block 1 7 Right adjusting block 1 8 Rear wheel 1 9 Brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 155: ...t Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Rear brake disc 1 3 Collar 1 4 Rear wheel sprocket 1 5 Rear wheel drive hub 1 6 Rear wheel drive hub damper 6 7 Collar 1 8 Oil seal 1 9 Bearing 1 10 Rear wheel 1 For installation reverse the removal proce dure ...

Page 156: ...REAR WHEEL 4 13 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 For assembly reverse the disassembly pro cedure ...

Page 157: ... forward and remove the drive chain from the rear wheel sprocket EAS22091 CHECKING THE REAR WHEEL 1 Check Wheel axle Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 7 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 17 and CHECKING THE WHEELS on page 3 17 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on pa...

Page 158: ... Install Wheel bearings Oil seal Refer to ASSEMBLING THE FRONT WHEEL on page 4 8 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 o...

Page 159: ...wer chamfer c faces to the bottom of the vehicle 5 Install Rear brake caliper Rear brake caliper retaining bolts 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 7 Tighten Wheel axle nut Rear brake caliper retaining bolts WARNING EWA13500 Make sure the brake hose is routed prop erly TIP When tightening the wheel axle nut there should be no clearance a between the ad...

Page 160: ...REAR WHEEL 4 17 ...

Page 161: ... ty Remarks The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Reflector bracket 1 4 Reflector 1 5 Brake pad clip 2 6 Brake pad pin 1 7 Brake pad spring 1 8 Brake pad 2 9 Bleed screw 1 For installation reverse the removal proce dure ...

Page 162: ... Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch lead connector 2 Disconnect 6 Front brake light switch 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 For assembly reve...

Page 163: ...T BRAKE 4 20 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 164: ...ng procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Front brake caliper 1 5 Reflector bracket 1 6 Reflector 1 For installation reverse the removal proce dure ...

Page 165: ...s The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 166: ... 1 Remove Front wheel Refer to FRONT WHEEL on page 4 5 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc deflection turn the handlebar to the left or right to ensure that the fron...

Page 167: ... Remove Brake hose holder Front brake caliper Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the ho...

Page 168: ...S The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22361 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of...

Page 169: ...als and brake caliper piston seals EAS22411 ASSEMBLING THE FRONT BRAKE CALI PERS WARNING EWA13621 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the brake caliper piston dust seals and brake cali per piston seals to swell and distort Whenever a brake caliper is disa...

Page 170: ...ult in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to ...

Page 171: ...heck Brake master cylinder reservoir 1 Brake master cylinder reservoir dia phragm holder 2 Cracks damage Replace Brake master cylinder reservoir dia phragm 3 Damage wear Replace 4 Check Brake hose 1 Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MAS TER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new br...

Page 172: ...parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 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 fluid...

Page 173: ...FRONT BRAKE 4 30 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 ...

Page 174: ...ear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 For installation reverse the removal proce dure ...

Page 175: ...GENERAL CHASSIS on page 4 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Brake fluid reservoir cover 1 7 Rear brake light switch coupler 1 Disconnect 8 Brake hose union bolt 1 9 Brake hose gasket 2 10 ...

Page 176: ...ake master cylinder Order Job Parts to remove Q ty Remarks 11 Right footrest assembly 1 12 Rear brake light switch 1 13 Rear brake master cylinder assembly 1 For installation reverse the removal proce dure 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R ...

Page 177: ...e rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 178: ...E 4 35 Removing the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure ...

Page 179: ... Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 180: ...to REAR WHEEL on page 4 11 2 Check Rear brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC...

Page 181: ...to contact the brake pads Remove any excess grease e Install the brake pads and brake pad spring TIP The longer tangs a of the brake pad spring must point in the direction of the brake caliper piston 3 Lubricate Rear brake caliper retaining bolt front ECA2S31022 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug ...

Page 182: ...er piston 1 Brake caliper piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 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 b Remove the brake caliper piston ...

Page 183: ...internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER...

Page 184: ...d cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 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 13 7 Check Brake...

Page 185: ...Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components 1 Install Brake master cylinder kit EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Brake hose gaskets Brake hose Brake fluid reservoir hose Brake hose union bolt WARNING EWA13530 Proper brake hose routing is essential to ins...

Page 186: ...gnificantly 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 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Ref...

Page 187: ...nnector 2 Disconnect 3 Front master cylinder holder 1 4 Front brake master cylinder assembly 1 5 Right handlebar switch 1 6 Throttle cable housing 2 7 Throttle cable 2 Disconnect 8 Grip end 2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 ...

Page 188: ...HANDLEBAR 4 45 Removing the handlebar Order Job Parts to remove Q ty Remarks 15 Upper handlebar holder 2 16 Handlebar 1 17 Lower handlebar holder 2 For installation reverse the removal proce dure ...

Page 189: ...handle bar as this may dangerously weaken it EAS22931 INSTALLING THE HANDLEBAR 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 Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 ECA39P1407 First tighten the bolts on the front side of the upper handlebar holder and then on the rear si...

Page 190: ...n page 4 28 7 Install Throttle cable clamp 1 TIP Using side a of the master cylinder as a guide install the clamp between side a and protector 2 of the throttle cable decelerator cable with the claw down and the damper facing to the master cylinder When clamping protector 3 of the throttle cable accelerator cable should be on the throttle grip side 8 Install Clutch lever holder 1 Clutch cable TIP ...

Page 191: ...There should be 1 3 mm 0 04 0 12 in of clearance a between the handlebar grip and the grip end 10 Install Left handlebar switch TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 29 12 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page ...

Page 192: ...he following procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 5 1 Front fender 1 2 Band 1 Left side only 3 Upper bracket pinch bolt 1 Loosen 4 Cap bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure ...

Page 193: ...e applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Fork spring 1 5 Locknut 1 6 Outer tube 1 7 Dust seal 1 8 Oil seal clip 1 9 Oil seal 1 10 Washer 1 11 Damper rod assembly bolt 1 12 Copper washer 1 13 Damper rod assembly 1 14 Inner tube 1 For assembly reverse the disassembly pro cedure ...

Page 194: ...RONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Spacer 2 Locknut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the lock nut 3 and the spacer 2 TIP Use the side of the rod holder that is marked B c Hold the cap bolt and loosen the locknut d Remove the cap bolt e Remove ...

Page 195: ...ength a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air ECA39P1405 The front fork leg has a very sophisti cated internal construction which are particularly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork EAS23031 ASSEM...

Page 196: ...bolt along with the copper washer TIP While holding the damper rod assembly with the damper rod holder 1 tighten the damper rod assembly bolt 3 Lubricate Inner tube s outer surface 4 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 to the inner tube ECA14B1007 Make sure the numbered side of the oil seal faces bottom side TIP Before installing the oil seal lubricate its lips with lithium soa...

Page 197: ...t fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 10 Install Rod puller 1 Rod puller attachment M10 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Recommended oil Suspension oil 01 Quantity Lef...

Page 198: ...l level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 14 Install Fork spring 1 Spacer 2 Locknut 3 Cap bolt 4 along with the O ring a Remove the rod puller and rod puller attachment b Install the fork spring TIP Install the fork spring with the smaller diameter a facing up A c Install the locknut all the way onto the d...

Page 199: ...to the vehicle and tightening the lower bracket pinch bolts EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 Rod ...

Page 200: ...FRONT FORK 4 57 WARNING EWA13680 Make sure the brake hoses are routed prop erly ...

Page 201: ...ENERAL CHASSIS on page 4 1 Meter assembly Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 44 Front fork legs Refer to FRONT FORK on page 4 49 1 Upper headlight stay 1 2 Main switch coupler 2 Disconnect 3 Steering stem nut 1 4 Upper bracket 1 5 Front brake hose joint 1 Disconnect 6 Horn lead connector 2 Disconnect 7 Horn 1 8 Lower headlight stay 1 ...

Page 202: ... Parts to remove Q ty Remarks 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 12 Lower ring nut 1 13 Lower bracket 1 14 Bearing cover 1 15 Lower bearing dust seal 1 16 Upper bearing 1 17 Lower bearing 1 For installation reverse the removal proce dure ...

Page 203: ...1 Wash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing races ECA14270 If the bear...

Page 204: ...r 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 20 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 49 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem n...

Page 205: ...cover Refer to GENERAL CHASSIS on page 4 1 Brake fluid reservoir bolt Refer to REAR BRAKE on page 4 31 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 4 Relay arm 2 5 Self locking nut bolt collar 1 1 1 6 Connecting arm 1 7 Collar oil seal bearing 2 4 2 8 Self locking nut bolt collar 1 1 1 9 Rear shock absorber assembly 1 10 Collar 1 For installation reverse the ...

Page 206: ... a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 25 30 mm 0 98 1 18 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place t...

Page 207: ... the oil seals outside 3 Install Rear shock absorber assembly Connecting arm 1 Relay arms 2 TIP Install the rear shock absorber upper bolt and frame and connecting arm bolt from the right Install the rear shock absorber lower bolt relay arm and connecting arm bolt and relay arm and swingarm bolt from the left When installing the rear shock absorber assembly lift up the swingarm Recommended lubrica...

Page 208: ...ut Relay arm and connecting arm nut 3 Frame 4 Swingarm A Left side B Right side Rear shock absorber assembly upper nut 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly lower nut 40 Nm 4 0 m kgf 29 ft lbf Frame and connecting arm nut 40 Nm 4 0 m kgf 29 ft lbf Relay arm and swingarm nut 40 Nm 4 0 m kgf 29 ft lbf Relay arm and connecting arm nut 40 Nm 4 0 m kgf 29 ft lbf ...

Page 209: ...er to REAR SHOCK ABSORBER ASSEMBLY on page 4 62 Drive chain Refer to CHAIN DRIVE on page 4 69 1 Rear fender 1 2 Drive chain guard 1 3 Brake hose holder 2 4 Drive chain adjusting bolt locknut washer 2 2 2 5 Pivot shaft nut washer 1 1 6 Pivot shaft 1 7 Swingarm 1 8 Dust cover 2 9 Drive chain guide 1 10 Spacer 1 11 Bearing 2 12 Collar oil seal bearing 1 2 1 For installation reverse the removal proce ...

Page 210: ...play A by mov ing the swingarm from side to side If the swingarm has side to side play check the spacer bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft spacer bearings and dust cov ers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 70 S...

Page 211: ...ls out side 3 Install Swingarm Pivot shaft 4 Install Drive chain Refer to INSTALLING THE DRIVE CHAIN on page 4 71 Rear shock absorber assembly Connecting arm Relay arms Rear wheel Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 62 and REAR WHEEL on page 4 11 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 Recommended lubricant Lithium soap based grease Installed de...

Page 212: ...RIVE 4 69 EAS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 3 1 Drive chain 1 For installation reverse the removal proce dure ...

Page 213: ...ration b Calculate the length a of the 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Check Drive chain Stiffness...

Page 214: ... SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent 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 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 EAS39P1403 INSTALLING THE DRIVE C...

Page 215: ...ive sprocket nut Refer to ENGINE REMOVAL on page 5 3 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits Recommended lubricant Chain lubr...

Page 216: ...CHAIN DRIVE 4 73 ...

Page 217: ...HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 25 CHECKING THE VALVES AND VALVE GUIDES 5 26 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 30 GENERATOR 5 32 REMOVING THE GENERATOR 5 34 INSTALLING THE GENERATOR 5 34 STARTER CLUTCH 5 36 REMOVING THE STARTER CLUTCH 5 37 CHECKING THE DAMPER 5 37 CHECKING THE STARTER ...

Page 218: ...IL PUMP 5 60 CHECKING THE RELIEF VALVE 5 61 CHECKING THE OIL DELIVERY PIPES 5 61 CHECKING THE OIL STRAINER 5 61 ASSEMBLING THE OIL PUMP 5 61 INSTALLING THE OIL WATER PUMP 5 62 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 67 CHECKING THE CRANKCASE 5 67 ASSEMBLING THE CRANKCASE 5 67 CONNECTING RODS AND PISTONS 5 69 REMOVING THE CONNECTING RODS AND PISTONS 5 70 CHECKING TH...

Page 219: ... 5 84 REMOVING THE TRANSMISSION 5 89 CHECKING THE SHIFT FORKS 5 89 CHECKING THE SHIFT DRUM ASSEMBLY 5 90 CHECKING THE TRANSMISSION 5 90 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 91 INSTALLING THE TRANSMISSION 5 91 ...

Page 220: ...9P1501 To prevent sparking the plug remove all ignition coil couplers and fuel injector cou plers before cranking the engine TIP The difference in compression pressure between cylinders should not exceed 100 kPa 1 kgf cm 15 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If ...

Page 221: ...ENGINE INSPECTION 5 2 6 Install Spark plug 7 Install Ignition coils Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 222: ...rts to remove Q ty Remarks Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Joint 1 5 Drive sprocket cover 1 6 Plate 1 7 Drive sprocket nut 1 8 Washer 1 9 Drive sprocket 1 For installation reverse the removal proce dure ...

Page 223: ...ge 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 3 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler cover 1 4 Muffler clamp 1 Loosen 5 Muffler 1 6 Muffler gasket 1 7 Exhaust pipe 1 8 Exhaust pipe gasket 1 9 Exhaust pipe bracket 1 For installation reverse the removal proce dure ...

Page 224: ...age 7 6 Thermostat assembly Refer to THERMOSTAT on page 6 7 Oil cooler Refer to OIL COOLER on page 6 5 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Battery negative lead 1 Disconnect 2 Battery positive lead 1 Disconnect 3 Clutch cable 1 Disconnect 4 Ground lead 2 Disconnect 5 Starter motor lead 1 Disconnect 6 Ignition coil sub wire harness coupler 1 Disconnect ...

Page 225: ...y Remarks 7 Stator coil assembly lead coupler 1 Disconnect 8 Crankshaft position sensor lead coupler 1 Disconnect 9 Oil level switch lead coupler 1 Disconnect 10 Neutral switch connector 1 Disconnect 11 Speed sensor coupler 1 Disconnect For installation reverse the removal proce dure ...

Page 226: ...ove Q ty Remarks 1 Right front engine mounting bolt 1 1 2 Left front engine mounting bolt 1 3 Upper engine mounting bolt nut 1 1 4 Lower engine mounting bolt nut 1 1 5 Engine mounting adjust bolt 2 Loosen 6 Engine 1 For installation reverse the removal proce dure ...

Page 227: ...ounting bolt 1 Upper engine mounting bolt 2 TIP Do not install the engine mounting nuts 6 Install Left front engine mounting bolt 1 temporarily tighten Right front engine mounting bolt 1 2 temporarily tighten 7 Tighten Engine mounting adjust bolts TIP Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mounting adjust bolts Right front engine mounting bolt 2 50 Nm 5...

Page 228: ...he left front engine mounting bolt 1 and then tighten the right front engine mounting bolt 1 2 10 Install Shift arm 1 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 01476 Lower engine mounting nut 51 Nm 5 1 m kgf 37 ft lbf Upper engine mounting nut 51 Nm 5 1 m kgf 37 ft lbf Left front engine mounting bolt 45 Nm 4 5 m kgf 33 ft lbf Right front engine m...

Page 229: ...e crankcase EAS39P1501 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket Washer Drive sprocket nut 1 TIP While applying the rear brake tighten the drive sprocket nut Stake the drive sprocket nut 1 at a cutout a in the drive axle Drive sprocket nut 85 Nm 8 5 m kgf 61 ft lbf LOCTITE New ...

Page 230: ...to THROTTLE BODIES on page 7 6 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Cylinder identification sensor coupler 1 Disconnect 2 Cylinder identification sensor 1 3 Ignition coil coupler 4 Disconnect 4 Ignition coil 4 5 Spark plug 4 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Timing chain guide top side 1 For installation reverse the removal proce dure ...

Page 231: ...engine side Disconnect Refer to CLUTCH on page 5 45 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 Camshaft sprocket 2 8 Timing chain guide intake side 1 9 Timing chain guide exhaust side 1 10 Timing chain 1 For installation reverse the removal proce dure ...

Page 232: ... can be found when the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Intake camshaft caps 1 Exhaust camshaft caps 2 ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaust cam...

Page 233: ...rnal diameter a Install the camshaft into the cylinder head without the camshaft caps Camshaft wrench 90890 04162 YM 04162 Camshaft lobe dimension limit Intake A 35 750 35 850 mm 1 4075 1 4114 in Limit 35 650 mm 1 4035 in Intake B 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Exhaust A 34 750 34 850 mm 1 3681 1 3720 in Limit 34 650 mm 1 3642 in Exhaust B 27 950 28 050 mm 1 1004 1 104...

Page 234: ...and the camshaft caps as a set EAS23870 CHECKING THE TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the ca...

Page 235: ...ng chain tensioner rod TIP Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain tensioner housing a Install the timing chain tensioner spring timing chain tensioner spring seat and tim ing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and then push the timing chain tensioner rod 3 into the timing chain tensioner hous ing TIP Do not relea...

Page 236: ...e engine TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket bolt with the camshaft wrench 3 3 Install Exhaust camshaft 1 Intake camshaft 2 TIP Make sure the punch mark a on each cam shaft faces up 4 Install Intake camshaft caps Exhaust camshaft caps TIP Make sure each camshaft cap is installed in its original place Refer to the identifica...

Page 237: ...ng 6 Check Camshaft punch mark a Make sure the punch mark a on the camshaft is aligned with the camshaft cap alignment mark b 7 Install Timing chain tensioner gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 WARNING EWA39P1502 Always use a new timing chain tensioner gasket ECA5D01011 The arrow mark a on the timing chain tensioner should face up 8 Turn Crankshaft several turns clockwi...

Page 238: ...faces a of the cylinder head cover and cyl inder head cover gasket Apply bond Yamaha bond No 1215 Three bond No 1215 onto the mating surfaces b of the cylinder head cover gasket and cylin der head Tighten the cylinder head cover bolts in stages and in a crisscross pattern 13 Install Spark plugs Ignition coils 1 TIP Assemble ignition coils 1 in the direction shown in the illustration Cylinder head ...

Page 239: ...VAL on page 5 3 Intake camshaft Refer to CAMSHAFTS on page 5 11 Exhaust camshaft Refer to CAMSHAFTS on page 5 11 1 Coolant pipe 1 2 Fast idle plunger inlet hose 1 3 Coolant temperature sensor 1 4 Right front engine mounting bolt 2 1 5 Cylinder head 1 6 Cylinder head gasket 1 7 Dowel pin 2 For installation reverse the removal proce dure ...

Page 240: ... 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 head using...

Page 241: ...g surface with engine oil 4 Tighten 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 17 Cylinder head nut 1st 25 Nm 2 5 m kgf 18 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf 3rd Nut 1 7 10 80 Nut 8 9 100 Cylinder head bo...

Page 242: ...ngs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 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 243: ...move 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 244: ...alve seat width Refer to CHECKING THE VALVE SEATS on page 5 27 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 245: ... valve guide with the valve guide 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 Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance...

Page 246: ...placed always replace the valve stem seal EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylin der head Valve guide remover ø4 90890 04111 Valve guide remover 4 ...

Page 247: ...r the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine l...

Page 248: ...mpressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring free length Free length intake 38 62 mm 1 52 in Limit 36 69 mm 1 44 in Free length exhaust 38 62 mm 1 52 in Limit 36 69 mm 1 44 in b Installed length Installed compression spring force intake 130 60 150 20 N 13 32 15 32 kgf 29 36 33 76...

Page 249: ...e stem end with an oil stone 2 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 Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by...

Page 250: ...ad with the recommended lubricant 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 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Recom...

Page 251: ...NERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Stator coil assembly lead coupler 1 Disconnect 2 Plug 1 3 Idle adjust screw holder 1 4 Generator rotor cover 1 5 Gasket 1 6 Dowel pin 2 7 Generator rotor assembly 1 8 Stator coil assembly lead holder 1 9 Stator coil assembly 1 10 Dowel pin 2 ...

Page 252: ...moving the generator Order Job Parts to remove Q ty Remarks 11 Bearing housing 1 12 Collar 1 13 Bearing 1 14 Starter clutch idler gear 1 15 Idler gear shaft 1 16 Bearing 1 For installation reverse the removal proce dure ...

Page 253: ...ly loosened remove them 2 Remove Generator rotor and starter clutch assem bly 1 3 Remove Idle gear shaft bolt 1 Washer Idle shaft Idle gear 2 EAS24500 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bolt 2 2 Install Generator rotor and starter clutch assem bly 1 3 Apply Sealant onto the stator coil lead grommet 1 Idle gear shaft bolt 10 Nm 1 0 m kgf 7 2 ft lbf...

Page 254: ...tor cover 1 TIP First tighten the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern Generator rotor cover bolt M8 22 Nm 2 2 m kgf 16 ft lbf Generator rotor cover bolt M6 12 Nm 1 2 m kgf 8 7 ft lbf New ...

Page 255: ...r Job Parts to remove Q ty Remarks 1 Spacer 1 2 O ring 1 3 Washer 1 4 Starter clutch drive gear 1 5 Collar 1 6 Washer 1 7 Driven gear 1 8 Damper 3 9 Starter clutch assembly plate 1 10 Starter clutch assembly 1 11 Generator rotor 1 For installation reverse the removal proce dure ...

Page 256: ...n gear 1 Dampers 2 4 Remove Starter clutch assembly plate 1 Starter clutch assembly 2 EAS5D01018 CHECKING THE DAMPER 1 Check Dampers 1 Damage wear Replace EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s ...

Page 257: ...ch drive gear clockwise B it should turn freely other wise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch assembly 1 Starter clutch assembly plate 2 EAS24590 Be sure to install the starter clutch assem bly to the driven gear so that the white paint mark is outside 2 Install Generator rotor 1 Dampers 2 Driven gear 3 TIP Be sure to i...

Page 258: ...y Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Crankshaft position sensor 1 3 Plug 1 4 Pickup rotor cover 1 5 Gasket 1 For installation reverse the removal proce dure ...

Page 259: ...lt 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 EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup rotor cover 1 O rings Crankshaft position sensor 2 Connect Crankshaft position sensor lead coupler Pickup rotor cover bolt 12 Nm 1 2 m kgf 8 7 ft lbf Crankshaft position sensor bolt 10 Nm 1 0 m kgf 7 2 ft l...

Page 260: ...marks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 6 Right throttle body joint Refer to THROTTLE BODIES on page 7 6 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 261: ...embly and rear cover replace the starter motor assembly Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 262: ...e the armature assembly resis tances with the digital circuit tester b If any resistance is out of specification replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer ...

Page 263: ... STARTER MOTOR 1 Install Brush holder set 2 Install Rear cover 1 Starter motor yoke 2 Front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 264: ...r Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 265: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal proce dure ...

Page 266: ...essure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 Green paint mark 6 Clutch plate 1 6 7 Friction plate 2 6 Purple paint mark 8 Clutch boss nut 1 9 Washer 1 10 Clutch boss 1 11 Wire circlip 1 12 Clutch plate 2 1 13 Friction plate 3 1 14 Clutch damper spring 1 15 Clutch damper spring seat 1 ...

Page 267: ...CLUTCH 5 48 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Thrust plate 1 17 Clutch housing 1 18 Bearing 1 For installation reverse the removal proce dure ...

Page 268: ...y loosened remove them 2 Remove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 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 Universal clutch holder 90890 04086 YM 91042 ...

Page 269: ... EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set TIP Measure the friction plate at four places EAS25111 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutc...

Page 270: ...age 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 will cause erratic clutch operatio...

Page 271: ...Clutch damper spring seat 1 Clutch damper spring 2 2 Install Friction plate 3 1 Clutch plate 2 2 3 Install Wire circlip 1 4 Install Clutch housing 1 TIP Make sure to fit the projections a of the oil water pump assembly drive sprocket to the concave b of the clutch housing 5 Install Thrust plate Clutch boss assembly 1 Washer Clutch boss nut 2 TIP Install the washer on the main axle with the OUT mar...

Page 272: ...te shifting half phase Assemble friction plate 1 to the clutch boss assembly so that red paint marks a on fric tion plate 1 is aligned with red paint mark b of friction plates 2 and 3 as shown in the illustration 8 Install Bearing Pull rod 1 Pressure plate 2 Clutch springs Clutch spring bolts 3 TIP Apply lithium soap based grease onto the pull rod Position the pull rod so that the teeth a face tow...

Page 273: ...ll lever TIP Install the pull lever with the O mark facing towards lower side When installing the pull lever push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 12 Clutch ...

Page 274: ...r to CLUTCH on page 5 45 Shift arm and shift rod Refer to ENGINE REMOVAL on page 5 3 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Shift shaft spring 1 6 Collar 1 7 Shift shaft spring stopper 1 8 Stopper lever 1 9 Washer 1 10 Stopper lever spring 1 11 Bearing 1 12 Oil seal 1 13 Bearing 1 For installation reverse the removal proce dure ...

Page 275: ...SHIFT SHAFT 1 Install Washer Stopper lever 1 Shift shaft spring stopper 2 Stopper lever spring 3 TIP Hook the ends of the stopper lever spring onto the stopper lever and the spring hook Mesh the stopper lever with the shift drum segment assembly 2 Install Bearing Washer Collar Shift shaft spring 1 Shift shaft 2 TIP Hook the end of the shift shaft spring onto the shift shaft spring stopper 3 Instal...

Page 276: ...E OIL on page 3 23 O2 sensor Refer to ENGINE REMOVAL on page 5 3 Muffler Refer to ENGINE REMOVAL on page 5 3 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 Clutch assembly Refer to CLUTCH on page 5 45 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 lead holder 1 3 O...

Page 277: ... strainer 1 9 Oil pipe 1 10 Oil delivery pipe 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 278: ...ng the oil pump 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 Pin 2 6 Oil pump rotor assembly 1 7 Pin 1 For assembly reverse the disassembly pro cedure ...

Page 279: ...il water pump assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump housing 2 Cracks damage wear Replace the defective part s 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 defec tive part s Inner rotor to ...

Page 280: ...CKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 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 EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the reco...

Page 281: ... WATER PUMP 1 Install O ring 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 ECA5D01016 After installing the oil water pump assem bly drive chain and drive sprocket make sure the oil water pump turns smoothly TIP Install the oil water pump assembly drive chain 1 onto the oil water pump assembly drive...

Page 282: ...Dowel pins Gasket Oil pan 1 Oil level switch 2 Engine oil drain bolt 3 WARNING EWA12820 Always use new copper washers Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil delivery pipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil strainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil pipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil pan bolt 12 Nm 1 2 m kgf 8 7 ft lbf ...

Page 283: ...OIL PUMP 5 64 TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with lith ium soap based grease ...

Page 284: ...MOVAL on page 5 3 Cylinder head Refer to CYLINDER HEAD on page 5 20 Shift shaft assembly Refer to SHIFT SHAFT on page 5 55 Crankshaft position sensor Refer to CRANKSHAFT POSITION SEN SOR on page 5 39 Oil water pump assembly Refer to OIL PUMP on page 5 57 Starter motor Refer to ELECTRIC STARTER on page 5 41 1 Oil return pipe 1 2 Speed sensor 1 3 Neutral switch 1 ...

Page 285: ...ng the crankcase Order Job Parts to remove Q ty Remarks 4 Crankcase breather hose 1 5 Ventilation chamber cover 1 6 Ventilation chamber cover gasket 1 7 Left side cover 1 8 O ring 1 9 Lower crankcase 1 10 Dowel pin 3 For installation reverse the removal proce dure ...

Page 286: ...it can be reinstalled in its original place 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 bearing inner surface with...

Page 287: ...e bearing surface Tighten the bolts in the tightening sequence cast on the crankcase M9 105 mm 4 1 in bolts with washers 1 10 M8 60 mm 2 4 in bolt 11 M8 60 mm 2 4 in bolts 12 16 M8 50 mm 2 0 in bolts 13 15 M6 70 mm 2 8 in bolts 19 21 23 M6 65 mm 2 5 in shoulder bolts 17 18 M6 60 mm 2 4 in bolt and copper washer 22 M6 60 mm 2 4 in bolts 24 25 M6 50 mm 2 0 in bolts 20 26 Following the tightening ord...

Page 288: ... Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 65 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 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 289: ...to 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 th...

Page 290: ...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 68 000 68 010 mm 2 6772 2 6776 in Taper limit 0 050 mm 0 0020 in Out of round limit...

Page 291: ... 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrica tion system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 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 Piston ring end gap Top ring 0 25 0 35 mm 0 0098...

Page 292: ...gs must be installed in their orig inal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the connecting rod and the big 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 Plastig...

Page 293: ... that the sections shown a and b are flush with each other by touching the surface TIP To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment f Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi tion TI...

Page 294: ... each other by touch ing the surface k Remove the connecting rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crank shaft 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 ...

Page 295: ... rod bolts using the plastic region tightening angle method Always install new bolts TIP Install by carrying out the following procedures in order to assemble in the most suitable con dition a Replace the connecting 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 c...

Page 296: ...ctive connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod faces left when the punch mark b on the piston is pointing up as shown Install the piston pin clips so that the clip ends are 3 mm 0 12 in c or more from the cutout in the piston Reinstall each piston into its original cylinder 5 Lubricate Piston Piston...

Page 297: ...re that the projection 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...

Page 298: ...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 WARNING EWA39P1503 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to...

Page 299: ...to CRANKCASE on page 5 65 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 70 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Washer 1 5 Timing chain drive sprocket 1 6 Straight key 1 7 Pickup rotor 1 8 Oil nozzle 4 For installation reverse the removal proce dure ...

Page 300: ...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 be installed in their original positions a Clean the crankshaft journal be...

Page 301: ...gs 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 determine the replacement cra...

Page 302: ...pper bearings into the upper crankcase Crankshaft journal lower bearings into the lower crankcase Crankshaft TIP Align the projections a on the crankshaft journal bearings 1 with the notches b in the crankcase Be sure to install each crankshaft journal bearings in its original place ...

Page 303: ...ve Q ty Remarks Lower crankcase Separate Refer to CRANKCASE on page 5 65 1 Drive axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift fork guide bar retainer 2 6 Spring 2 7 Shift fork guide bar 2 8 Shift fork L 1 9 Shift fork R 1 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle retainer 1 13 Main axle assembly 1 ...

Page 304: ...SSION 5 85 Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 14 Oil pipe 1 15 Oil baffle plate 1 16 Bearing 2 For installation reverse the removal proce dure ...

Page 305: ...ar 1 install the gear with groove a facing to the toothed lock washer 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 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 assembly reverse the disassembly pro cedure ...

Page 306: ...sher 1 2 1st wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 18 Collar 1 19 2nd wheel gear 1 ...

Page 307: ...TRANSMISSION 5 88 Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 20 Collar 1 21 Bearing 1 22 Circlip 1 23 Drive axle 1 For assembly reverse the disassembly pro cedure ...

Page 308: ...ing b Tighten the bolts 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 pipe 1 Bearing 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 f...

Page 309: ...2 Damage pitting Replace the shift drum assembly EAS26280 CHECKING THE 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 Tran...

Page 310: ... 2 Install Toothed lock washer retainer 1 Toothed 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 T...

Page 311: ...k L 1 and R 2 Drive axle assembly 3 Shift fork guide bar Shift fork guide bar retainer 4 TIP Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make sure that the drive axle bearing circlip a is inserted into the grooves in the upper crankcase 4 Check Transmission Rough movement Repair TIP Oil each gear shaft and bear...

Page 312: ...TRANSMISSION 5 93 ...

Page 313: ...R 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 9 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 9 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 ...

Page 314: ...Air filter case Refer to GENERAL CHASSIS on page 4 1 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Radiator side cover 2 2 Coolant reservoir hose 1 Disconnect 3 Radiator inlet hose 1 Disconnect 4 Water pump breather hose 1 1 Disconnect 5 Oil cooler outlet hose 1 6 Radiator outlet hose 1 7 Radiator upper cover 1 ...

Page 315: ... Order Job Parts to remove Q ty Remarks 8 Radiator fan motor coupler 2 Disconnect 9 Radiator 1 10 Radiator fan motor 2 11 Water pump breather hose 2 1 Disconnect 12 Water pump inlet pipe 1 For installation reverse the removal proce dure ...

Page 316: ...k Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 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 26 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 Rad...

Page 317: ...2 7 kPa 1 23 kgf cm 17 8 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 318: ...efer to CHANGING THE COOLANT on page 3 26 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Water jacket joint inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler union bolt 1 4 Washer 1 5 Oil cooler 1 6 Water pump outlet pipe 1 7 Water jacket joint 1 For installation reverse the removal proce dure ...

Page 319: ...soap based grease to the O ring Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 23 4 Check Cooling sy...

Page 320: ...e Refer to GENERAL CHASSIS on page 4 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 6 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Band 1 2 Radiator inlet hose 1 3 Thermostat assembly 1 4 Thermostat assembly inlet hose 1 5 Coolant reservoir breather hose 1 6 Coolant reservoir hose 1 7 Coolant reservoir cap 1 8 Coolant reservoir tank 1 For installation reverse the removal...

Page 321: ...ERMOSTAT 6 8 Disassembling the thermostat assembly Order Job Parts to remove Q ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly pro cedure ...

Page 322: ... s indicated tem perature TIP If the accuracy of the thermostat 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 EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 TIP Install the thermostat with its breath...

Page 323: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 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 324: ...remove Q ty Remarks Oil water pump assembly Refer to OIL PUMP on page 5 57 Oil pump rotor Refer to OIL PUMP on page 5 57 1 Water pump cover 1 2 Pin 2 3 Impeller shaft along with the impeller 1 4 Water pump seal 1 5 Oil seal 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 325: ... not scratch the impeller shaft EAS26541 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the oil water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Bearing 1 Oil seal 2 i...

Page 326: ...mpeller shaft tilt Out of specification Repeat steps 3 and 4 ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanical seal installer 4 Middle driven shaft bearing...

Page 327: ...E FUEL TANK COVER 7 5 CHECKING THE FUEL PRESSURE 7 5 THROTTLE BODIES 7 6 REMOVING THE FUEL HOSE THROTTLE BODY SIDE 7 9 CHECKING THE FUEL INJECTORS 7 9 INSTALLING THE INJECTORS 7 9 CHECKING THE INJECTOR PRESSURE 7 9 CHECKING AND CLEANING THE THROTTLE BODIES 7 10 INSTALLING THE FUEL HOSE THROTTLE BODY SIDE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 ...

Page 328: ...or 1 Disconnect 4 Fuel sender coupler 1 Disconnect 5 Fuel pump coupler 1 Disconnect 6 Fuel tank drain hose 1 Disconnect 7 Fuel tank breather hose 1 Disconnect Except for California 8 Fuel tank breather hose fuel tank to rollover valve 1 Disconnect For California only 9 Fuel tank 1 10 Fuel pump bracket 1 11 Fuel pump 1 12 Fuel pump gasket 1 13 Filler cap assembly 1 For installation reverse the remo...

Page 329: ... bolt Refer to REAR BRAKE on page 4 31 1 Rectifier regulator coupler 2 Disconnect 2 Rectifier regulator 1 3 Fuel tank breather hose fuel tank to rollover valve 1 4 Rollover valve 1 5 Canister purge hose 1 6 Fuel tank breather hose rollover valve to canis ter 1 7 Waterproof coupler 1 Disconnect 8 Canister cover 1 9 Canister 1 10 Canister breather hose 1 11 Rectifier regulator bracket 1 12 Canister ...

Page 330: ... with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose ECA14B1003 Be sure to disconnect the fuel hose by hand Do not forcefully 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 hose place a few rags ...

Page 331: ...shown in the illustra tion Align the projection a on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tightening sequence as shown EAS39P1704 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side Fuel hose connector cover ECA14B1033 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the...

Page 332: ...fuel tank bolt and hold up the fuel tank c Disconnect the fuel hose 1 from the fuel pump Refer to REMOVING THE FUEL TANK on page 7 3 WARNING EWA39P1702 Cover fuel hose connection with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose ECA14B1003 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose w...

Page 333: ...le handlebar side Disconnect Refer to HANDLEBAR on page 4 44 1 Fuel hose 1 2 Fuel injection system sub wire harness coupler 1 Disconnect 3 Sub throttle position sensor coupler 1 Disconnect 4 Throttle body hose 2 5 Canister purge hose 1 Disconnect For California only 6 Fast idle plunger outlet hose 1 Disconnect 7 Fast idle plunger inlet hose 1 Disconnect 8 Idle adjust screw wire 1 9 Throttle body j...

Page 334: ... 7 7 Removing the throttle bodies Order Job Parts to remove Q ty Remarks 11 Coolant temperature sensor coupler 1 Disconnect 12 Throttle bodies 1 13 Throttle body joint 2 For installation reverse the removal proce dure ...

Page 335: ... 11 4 Negative pressure hose Thick 4 5 Hose joint 2 For California only 6 Canister purge hose 3 For California only 7 Intake air pressure sensor 1 8 Throttle position sensor 1 9 Sub throttle position sensor 1 10 Idle adjust screw wire 1 11 Air screw set 4 12 Collar 1 13 Fuel rail 2 14 Fuel rail joint 1 15 Fuel injector 4 For installation reverse the removal proce dure ...

Page 336: ... the battery terminal before checking the injectors ECA39P1701 When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rail or O rings If an injector is subject to strong shocks or excessive force replace it 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 8 31 EAS39P1705 INSTALLING THE INJECTORS ECA39P1702 Always use ...

Page 337: ...HECKING AND CLEANING THE THROT TLE BODIES TIP Before cleaning the throttle bodies check the following items Valve clearance Spark plugs Compression pressure Air filter element Throttle body joints Fuel hose Air induction system Exhaust system Breather hoses Vacuum hoses Throttle body hoses Canister purge hoses for California only Fast idle plunger inlet hose Fast idle plunger outlet hose WARNING E...

Page 338: ...odies be care ful not to injure yourself on the throttle valves or other components of the throttle bodies ECA39P1704 Do not open the sub throttle valves by sup plying electrical power to the throttle bod ies d Apply a petroleum based solvent to the throttle valves and the inside of the throttle bodies to remove any carbon deposits TIP Do not allow any petroleum based solvent to enter the opening ...

Page 339: ...he 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 rail joint until a distinct click is heard To install the fuel hose onto the fuel rail joint slide the fuel hose connector cover 1 on the end of the hose in the...

Page 340: ...NSOR WARNING EWA39P1701 Handle the sub throttle position sensor with special care Never subject the sub throttle position sensor to strong shocks If the sub throt tle position sensor is dropped replace it 1 Check Sub throttle position sensor Refer to CHECKING THE SUB THROT TLE POSITION SENSOR on page 8 115 2 Adjust Sub throttle position sensor angle a Remove the throttle bodies and temporarily tig...

Page 341: ...in the spec ified range g After adjusting the sub throttle position sensor angle tighten the sub throttle posi tion sensor screw 2 h Remove the test harness 3P sub throttle position sensor and install the throttle bod ies Positive tester probe Green yellow wire harness color Negative tester probe Black blue wire harness color Output voltage 0 3 0 4 V Sub throttle position sensor screw 3 5 Nm 0 35 ...

Page 342: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM ...

Page 343: ...AIR INDUCTION SYSTEM 7 16 1 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 344: ...AL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 1 Air induction system hose air cut off valve to reed valve cover 1 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air cut off valve coupler 1 Disconnect 4 Air cut off valve 1 5 Air induction system hose air filter case to air cut off valve 1 6 Reed valve cover 2 7 Reed valve assembly 2 8 Reed valve plate 4 For in...

Page 345: ...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 value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve...

Page 346: ... 7 19 Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 2 Install Reed valve cover A Exhaust side Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE ...

Page 347: ...DIAGRAM 8 13 TROUBLESHOOTING 8 15 LIGHTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 35 DIAGNOSTIC MODE 8 36 TROUBLESHOOTING DETAILS 8 37 DIAGNOSTIC CODE T...

Page 348: ... COIL 8 110 CHECKING THE RECTIFIER REGULATOR 8 111 CHECKING THE HORN 8 112 CHECKING THE ENGINE OIL LEVEL SWITCH 8 112 CHECKING THE FUEL SENDER 8 112 CHECKING THE OIL LEVEL WARNING LIGHT 8 113 CHECKING THE SPEED SENSOR 8 113 CHECKING THE RADIATOR FAN MOTORS 8 114 CHECKING THE COOLANT TEMPERATURE SENSOR 8 114 CHECKING THE THROTTLE POSITION SENSOR 8 115 CHECKING THE SUB THROTTLE POSITION SENSOR 8 115...

Page 349: ......

Page 350: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 351: ...utral switch 16 Sidestand switch 19 Lean angle sensor 22 Cylinder identification sensor 23 Crankshaft position sensor 24 ECU engine control unit 25 Ignition coil 1 26 Ignition coil 2 27 Ignition coil 3 28 Ignition coil 4 29 Spark plug 53 Right handlebar switch 55 Engine stop switch 58 Left handlebar switch 59 Clutch switch 80 Ignition fuse ...

Page 352: ...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 353: ...M 8 4 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Neutral switch 12 Battery negative lead ...

Page 354: ... 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 8 108 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 108 Replace the ignition coils 6 Check the crankshaft position sen sor Re...

Page 355: ...S on page 8 97 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 105 Replace the relay unit 14 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 107 Replace the relay unit 15 Check the lean angle sensor R...

Page 356: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 357: ...d 7 Engine ground 8 Battery 10 Starter relay 11 Starter motor 12 Relay unit 13 Starting circuit cut off relay 15 Neutral switch 16 Sidestand switch 53 Right handlebar switch 55 Engine stop switch 56 Start switch 58 Left handlebar switch 59 Clutch switch 80 Ignition fuse ...

Page 358: ...sed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions h...

Page 359: ...STAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Diode 13 Starter relay 14 Starter motor ...

Page 360: ...inals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 110 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 43 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer ...

Page 361: ...SWITCHES on page 8 97 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the right handlebar switch 14 Check the entire starting system s wiring R...

Page 362: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 363: ...CHARGING SYSTEM 8 14 2 Rectifier regulator 3 AC magneto 5 Main fuse 6 Frame ground 7 Engine ground 8 Battery ...

Page 364: ...CHECKING AND CHARGING THE BATTERY on page 8 102 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 110 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 111 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGR...

Page 365: ...CHARGING SYSTEM 8 16 ...

Page 366: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 367: ...ine ground 8 Battery 24 ECU engine control unit 42 Meter assembly 49 High beam indicator light 51 Meter light 58 Left handlebar switch 60 Dimmer switch 69 Headlight 70 License plate light 71 Tail brake light 72 Headlight relay on off 78 Headlight fuse 80 Ignition fuse ...

Page 368: ... 100 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight and ignition Refer to CHECKING THE FUSES on page 8 101 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 102 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the main switch 5 Check the dimmer swi...

Page 369: ...LIGHTING SYSTEM 8 20 NG OK 7 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 370: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 371: ... light 45 Tachometer 46 Multi function meter 50 Turn signal indicator light 52 Oil level switch 53 Right handlebar switch 54 Front brake light switch 57 Rear brake light switch 58 Left handlebar switch 61 Turn signal switch 62 Horn switch 63 Horn 64 Turn signal relay 65 Rear right turn signal light 66 Rear left turn signal light 67 Front right turn signal position light 68 Front left turn signal p...

Page 372: ...fer to CHECKING THE FUSES on page 8 101 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 102 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair th...

Page 373: ...ocket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the rear brake light switch 4 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 circui...

Page 374: ...ck the neutral switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 107 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the oil level switch Refer...

Page 375: ...iring Replace the ECU or meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 113 Replace the speed sensor 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 ECU or meter assembly 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENS...

Page 376: ...COOLING SYSTEM 8 27 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 377: ... ground 7 Engine ground 8 Battery 24 ECU engine control unit 39 Coolant temperature sensor 73 Radiator fan motor relay 74 Right radiator fan motor fuse 75 Right radiator fan motor 76 Left radiator fan motor fuse 77 Left radiator fan motor 80 Ignition fuse ...

Page 378: ...ND CHARGING THE BATTERY on page 8 102 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 114 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 105 Replace t...

Page 379: ...COOLING SYSTEM 8 30 NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or repair the cooling system s wiring Replace the ECU ...

Page 380: ...FUEL INJECTION SYSTEM 8 31 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 381: ... sensor 24 ECU engine control unit 25 Ignition coil 1 26 Ignition coil 2 27 Ignition coil 3 28 Ignition coil 4 29 Spark plug 30 Injector 1 31 Injector 2 32 Injector 3 33 Injector 4 34 Air induction system solenoid 35 Sub throttle servo motor 36 Sub throttle position sensor 37 Intake air pressure sensor 38 Throttle position sensor 39 Coolant temperature sensor 40 Intake air temperature sensor 41 O2...

Page 382: ...splayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been set to O...

Page 383: ...ng 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 operating or stop operating depending on the condi...

Page 384: ...tory The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sen sors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 37 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 the inn...

Page 385: ...D 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 buttons TIP The diagnostic code number appears on the clock LCD d01 d70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the...

Page 386: ...upler 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 wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or loc...

Page 387: ...eck or maintenance 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 ...

Page 388: ...r short circuit detected no nor mal signals are received from the intake air pressure sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 03 Meter display Displays the intake air pressure Procedure Set the engine stop switch to and then operate the throttle while pushing the start switch If the display value changes the performance is OK Item components and prob...

Page 389: ...cuit Replace the wire harness Black blue Black blue Pink white Pink white Blue Blue 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 Sensor installation status Check the mounting sec tion for loose or pinched mounting Incorrect installation Rein stall or repair the sensor Place the main switch ...

Page 390: ...re sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 117 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 7 ECU malfunction Replace the ECU Fault code No 13 Item Intake air pressure sensor open or short circuit detected no nor mal signals are received f...

Page 391: ...ed discon nected clogged twisted or bent Repair or replace the sensor hose 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 2 Intake air pressure sensor malfunction Check in the diagnostic mode Code No d03 When engine is stopped Atmospheric pressure at the current altitude and weath...

Page 392: ...r 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 fuel injection system sub wire harness coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor ...

Page 393: ...on Check the diagnostic mode Code No d01 When throttle is fully closed A value of 14 20 is indicated If the indication is outside of range Replace the throttle position 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 8 ECU malfunction Replace the ECU Fault code No 15 Item Throttle positio...

Page 394: ...sor inspection proce dure 1 Sensor installation status Check for loose mounting pinched mounting or hard mounting Make sure that the mounting position is correct Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 12 Place the main switch to the ON position and then open and close the throttle No fault code indicated Recovered Fault code indicated Check the next step 2 Throttle position sen...

Page 395: ...nection of wire 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 when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Chec...

Page 396: ...d Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Item Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected no normal signals are received from the sidestand switch Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No d 20 Meter display Sidestand switch ON sidestand retracted OFF...

Page 397: ...ped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 3000 m above sea level Approx 70 kPa Incorrect indication Sensor malfunction Replace the intake air pressure sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 117 Place the main switch to the ON position and check the fault code indicat...

Page 398: ... Connection of wire 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 Fault code No 20 Item Int...

Page 399: ...he ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 Coolant temperature sensor malfunction Check in the diagnostic mode Code No d06 During cold starting A tem perature close to the ambient temperature is indicated Indication is incorrect Replace the coolant tempera ture sensor Sensor inspection procedure Refer to CHECKING ...

Page 400: ...indicated Recovered Fault code indicated Check the next step 2 Connection of wire 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 Faul...

Page 401: ...Meter display Displays the atmospheric pressure Procedure Compare the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of atmospheric pressure sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor conn...

Page 402: ...dicated Recovered Fault code indicated Check the next step 4 Installation status of atmo spheric pressure sensor Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct 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 Fault code No 23 Item Atmos...

Page 403: ...C PRES SURE SENSOR on page 8 116 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 23 Item Atmospheric pressure sensor open or short circuit detected no normal signals are received from the atmospheric pressure sensor Fail safe system Able to start e...

Page 404: ...fault code indicated Recovered Fault code indicated Check the next step 3 Connection of wire 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 d63 No fault cod...

Page 405: ... Check or maintenance 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 ...

Page 406: ...il five times at one second inter vals Illuminates the engine trouble warning light Procedure Check that a spark is generated 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 lock...

Page 407: ... 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 5 seconds Then check the fault ...

Page 408: ...ted 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 409: ... 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 mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fault c...

Page 410: ...ted 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 411: ...reen 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 approximately 5 seconds Then check the fau...

Page 412: ...ted 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 413: ...reen 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 mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fault...

Page 414: ...ce the defective ECU Fault code No 36 Item Cylinder 4 ignition coil open or short circuit detected in the pri mary lead of the cylinder 4 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No d 33 Actuation Actuates the cylinder 4 ignition coil five times at one second int...

Page 415: ...tuation Actuates injector 4 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 4 is actuated five times by listening for the operating sound Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Locate the malfunction Check in the diagnostic mode Code No d36 d37 d38 d39 Locate the injector with no opera...

Page 416: ...m the injector Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No d 36 d 37 d 38 d 39 d 36 Actuation Actuates injector 1 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 1 is actuated five times by listening for the operati...

Page 417: ...e number of faulty cylinders Diagnostic code No d 36 d 37 d 38 d 39 d 36 Actuation Actuates injector 1 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 1 is actuated five times by listening for the operating sound d 37 Actuation Actuates injector 2 five times at one second intervals Illuminates the engine trouble warning light Procedure ...

Page 418: ... the OFF position first and then 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 wire 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 R...

Page 419: ...ault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 41 Item Lean angle sensor open or short circuit detected no normal sig nals are received from the lean angle sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No d 08 Meter display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean ...

Page 420: ...e Able to drive vehicle Diagnostic code No d 21 Meter display Clutch switch ON Gear is in other than neutral operating clutch and storing side stand OFF Gear is in other than neutral operating clutch and using side stand Procedure Shift the transmission clutch lever and sidestand Item compo nents and probable cause Check or maintenance job Sensor inspec tion procedure Locate the mal function Check...

Page 421: ...nect it securely or repair replace the wire harness Check in the diagnostic code Code No d07 With the rear wheel rotated check the pulse input 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 Check in th...

Page 422: ... 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 Blue yellow Blue yellow Start the engine 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 4 Cont...

Page 423: ... 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 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 Connection of wire harness ECU coupler Check the connection of the coupler is sec...

Page 424: ...ge Approximately 12 0 Procedure Set the engine stop switch to and then compare the actually measured battery voltage with the meter display value If the actu ally measured battery voltage is low recharge the battery d 50 Actuation Actuates the main relay five times at one second intervals Illuminates the engine trouble warning light The engine trouble warning light is off when the relay is on and ...

Page 425: ...place the relay unit Place the main switch to the ON position for approxi mately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step Fault code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector fuel pump and main relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 0...

Page 426: ...epeating cycle Procedure Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 ECU malfunction Replace the ECU Fault code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector fuel pump and main relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 09 d 50 d 09 Meter display Fuel system voltage battery v...

Page 427: ...ble cause Check or maintenance job Sensor inspection proce dure 1 Installation status of sub throttle position sensor Check the mounting section for a loose or pinched mount ing 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 sub throttle position sensor coupler Check the connect...

Page 428: ...b throttle posi tion sensor Refer to CHARGING SYS TEM on page 8 13 Sub throttle position sensor malfunction Replace the sub throttle position 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 Replace the ECU Fault code No 47 Item Sub throttle position sensor open or short ...

Page 429: ...sition sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Check in the diagnostic code Code No d55 Check the sub throttle servo motor for proper operation 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 indicat...

Page 430: ...rive vehicle Diagnostic code No Meter display Procedure Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 ECU malfunction Replace the ECU Place the main switch to the ON position Then check that no fault code indicated Fault code No 48 Item Sub throttle servo motor stuck sub throttle servo motor detected signal from sub throttle position sensor will not cha...

Page 431: ...ion 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 wire harness ECU coupler Check the connection of the coupler is se...

Page 432: ...cation No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire 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 ind...

Page 433: ...ion No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire 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 indica...

Page 434: ...code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire 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...

Page 435: ...red Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No Er 4 Item ECU internal malfunction input signal error non registered data has been received from the meter Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item components and probable cause Check or maintenance job Sensor inspection proce dure ...

Page 436: ...arning 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 d 61 Malfunction history code display No history 00 History exists Fault code Nos d11 70 If more than ...

Page 437: ...responding fault code No the information is shown in DIAGNOSTIC CODE TABLE Refer to DIAGNOSTIC CODE TABLE on page 8 87 d 63 Malfunction code reinstate ment for fault code No d24 only No malfunction code 00 Malfunction code exists Fault code No d24 If more than one code number is detected the dis play alternates every two seconds to show all the detected code numbers When all code numbers are shown...

Page 438: ...FUEL PUMP SYSTEM 8 89 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 439: ...n switch 5 Main fuse 6 Frame ground 7 Engine ground 8 Battery 9 Fuel injection system fuse 12 Relay unit 14 Fuel pump relay 17 Fuel pump 24 ECU engine control unit 53 Right handlebar switch 55 Engine stop switch 80 Ignition fuse ...

Page 440: ...use s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 102 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 97 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKIN...

Page 441: ...FUEL PUMP SYSTEM 8 92 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 89 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 442: ...ELECTRICAL COMPONENTS 8 93 EAS27973 ELECTRICAL COMPONENTS ...

Page 443: ...lutch switch 4 Ignition coil 5 Main fuse 6 Battery 7 Fuse box 8 Fuel injection system fuse 9 Starter relay 10 Rectifier regulator 11 Rear brake light switch 12 O2 sensor 13 Speed sensor 14 Sidestand switch 15 Oil level switch 16 Neutral switch 17 Radiator fan motor 18 Horn ...

Page 444: ...ELECTRICAL COMPONENTS 8 95 ...

Page 445: ...uel pump 5 Atmospheric pressure sensor 6 Relay unit 7 Lean angle sensor 8 Turn signal relay 9 Headlight relay 10 Radiator fan motor relay 11 Coolant temperature sensor 12 Crankshaft position sensor 13 Sub throttle servo motor 14 Sub throttle position sensor 15 Throttle position sensor 16 Cylinder identification sensor ...

Page 446: ...ELECTRICAL COMPONENTS 8 97 EAS27981 CHECKING THE SWITCHES ...

Page 447: ... 1 Clutch switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Main switch 6 Oil level switch 7 Sidestand switch 8 Front brake light switch 9 Engine stop switch 10 Start switch 11 Neutral switch 12 Rear brake light switch ...

Page 448: ... 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 given switch p...

Page 449: ...lowing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight 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 ...

Page 450: ... Fuse a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical cir...

Page 451: ... be maintained and battery perfor mance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid bat tery should be charged according to the appropriate charging method If the bat tery is overcharged the electrolyte level will drop considerably Therefore ...

Page 452: ...er Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot ...

Page 453: ...aving the battery unused for more than 30 minutes Charging method using a constant voltage 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 cur...

Page 454: ...re harness 2 Connect the pocket tester Ω 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off 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 p...

Page 455: ...hown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continui...

Page 456: ...er YU 03112 C Positive tester probe Brown white 1 Negative tester probe Ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Yellow black 2 No continuity Positive tester probe Yellow black 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue yellow 3 No continuity Posi...

Page 457: ...ion coil terminals b Connect the pocket tester Ω 1 to the ignition coil as shown c Measure the primary coil resistance 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 Primary coil resistance 1 19 1 61 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester prob...

Page 458: ... position sensor resistance EAS28131 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the battery box 2 Check Lean angle sensor output 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 Minimum ignition spark gap 6 0 mm 0...

Page 459: ...eck 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 as shown Positive tester probe Yellow...

Page 460: ...ecification Replace the recti fier regulator a Set the engine tachometer to the ignition coil of cylinder 1 b Connect the pocket tester AC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the rectifier regulator output volt age Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket ...

Page 461: ... level switch resistance EAS39P1802 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank Horn resistance 1 066 1 114 Ω at 20 C 68 F Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Horn terminal 1 Negative tester probe Horn terminal 2 Oil level switch resistance Maximum level positi...

Page 462: ...tected in oil level switch Replace the oil level switch EAS28241 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the test harness speed sensor 3P 1 to the speed sensor coupler and wire harness as shown b Connect the pocket tester DC 20 V to the test harness speed sensor 3P c Set the main switch to ON d Elevate the rear wheel and slowly rotate it...

Page 463: ...cial care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1 k 100 to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperatur...

Page 464: ...sition sensor adjust its angle properly Refer to ADJUST ING THE THROTTLE POSITION SENSOR on page 7 12 EAS39P1803 CHECKING THE SUB THROTTLE POSITION SENSOR 1 Remove Sub throttle position sensor from the throttle body 2 Check Sub throttle position sensor a Connect the pocket tester Ω 1 k to the sub throttle position sensor as shown b Measure the sub throttle position sensor maximum resistance Out of...

Page 465: ...m solenoid resistance Out of specification Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester Ω 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure sensor output volt age Out of specif...

Page 466: ...AS28411 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 5S7 3P 1 to the intake air pressure sensor and wire harness as shown Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Test harness S pressure sen sor 5S7 3P 90890 03211 YU 03211 Positive tester pr...

Page 467: ...ster Ω 1 k 100 to the intake air temperature sensor termi nal as shown b Immerse the intake air 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 ...

Page 468: ...ELECTRICAL COMPONENTS 8 119 ...

Page 469: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 470: ...ornia only Clogged rollover valve hose for Califor nia only Deteriorated or contaminated fuel Clogged or damaged fuel hose 2 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 spa...

Page 471: ...el pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembl...

Page 472: ... OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil ...

Page 473: ...lty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty dimmer switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switc...

Page 474: ...tch 54 Front brake light switch 55 Engine stop switch 56 Start switch 57 Rear brake light switch 58 Left handlebar switch 59 Clutch switch 60 Dimmer switch 61 Turn signal switch 62 Horn switch 63 Horn 64 Turn signal relay 65 Rear right turn signal light 66 Rear left turn signal light 67 Front right turn signal position light 68 Front left turn signal position light 69 Headlight 70 License plate li...

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Page 477: ...WIRING DIAGRAM FZ8NA C ...

Page 478: ...WIRING DIAGRAM FZ8NA C ...

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