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Yamaha FJR1300R, Service Manual

The Yamaha FJR1300R Owner's Manual is a comprehensive guide for owners to understand and maintain their motorbike. This essential manual is available for free download from manualshive.com, offering users easy access to the necessary information needed to enhance their riding experience and ensure optimal performance of the FJR1300R.

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9 - 3

TRBL

SHTG

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/

FAULTY GEAR SHIFTING

EAS00848 

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to “STARTING PROBLEMS”.

ENGINE
Air filter

• Clogged air filter element

FUEL SYSTEM
Fuel pump

• Faulty fuel pump

EAS00850 

FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT

Refer to “CLUTCH DRAGS”.

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 assembled transmission

JUMPS OUT OF GEAR
Shift shaft

• Incorrect shift pedal position 
• Improperly returned stopper lever

Shift forks

• Worn shift fork

Shift drum

• Incorrect axial play 
• Worn shift drum groove

Transmission

• Worn gear dog

Summary of Contents for FJR1300R

Page 1: ...LIT 11616 16 18 5JW 28197 10 FJR1300R FJR1300RC SERVICE MANUAL...

Page 2: ...002 by Yamaha Motor Corporation U S A First edition June 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly pro...

Page 3: ...nformation changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamah...

Page 4: ...f each page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and c...

Page 5: ...fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication p...

Page 6: ......

Page 7: ...GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TR...

Page 8: ...TS 1 31 IMPORTANT INFORMATION 1 35 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 35 REPLACEMENT PARTS 1 35 GASKETS OIL SEALS AND O RINGS 1 35 LOCK WASHERS PLATES AND COTTER PINS 1 36 BEARINGS AND OIL SEAL...

Page 9: ...EM DIAGRAMS 2 38 CABLE ROUTING 2 42 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART...

Page 10: ...EM 3 47 CHANGING THE COOLANT 3 48 CHASSIS 3 51 ADJUSTING THE FRONT BRAKE 3 51 ADJUSTING THE REAR BRAKE 3 52 CHECKING THE BRAKE FLUID LEVEL 3 53 CHECKING THE BRAKE PADS 3 54 ADJUSTING THE REAR BRAKE LI...

Page 11: ...RAKE MASTER CYLINDER 4 26 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 27 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 30 FRONT BR...

Page 12: ...CK ABSORBER ASSEMBLY 4 86 CHECKING THE CONNECTING ARM AND RELAY ARM 4 86 INSTALLING THE RELAY ARM 4 87 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 87 SWINGARM 4 88 REMOVING THE SWINGARM 4 90 CHECKIN...

Page 13: ...HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5...

Page 14: ...ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PUMP 5 63 INSTALLING THE OIL STRAINER 5 63 INSTALLING THE OIL PAN 5 63 MIDDLE GEAR 5 65 REMOVING THE MIDDLE GEAR 5 69 DISASSEMBLING THE MIDDLE DRIVE SH...

Page 15: ...DRUM ASSEMBLY 5 115 CHECKING THE TRANSMISSION 5 115 INSTALLING THE TRANSMISSION 5 117 BALANCERS 5 118 FRONT BALANCER 5 118 REAR BALANCER 5 119 CHECKING THE BALANCER 5 120 INSTALLING THE FRONT BALANCER...

Page 16: ...7 38 AIR INDUCTION SYSTEM 7 40 AIR INJECTION 7 40 AIR CUT OFF VALVE 7 40 AIR INDUCTION SYSTEM DIAGRAMS 7 41 AIR CUT OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 7 42 REED VALVES 7 43 CHECKING THE...

Page 17: ...8 30 CHECKING THE LIGHTING SYSTEM 8 32 SIGNALING SYSTEM 8 36 CIRCUIT DIAGRAM 8 36 TROUBLESHOOTING 8 38 CHECKING THE SIGNALING SYSTEM 8 39 COOLING SYSTEM 8 46 CIRCUIT DIAGRAM 8 46 TROUBLESHOOTING 8 47...

Page 18: ...ATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 6...

Page 19: ...YCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL CODE The model code label 1 is af...

Page 20: ...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 sys...

Page 21: ...the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake tempera...

Page 22: ...tmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throt...

Page 23: ...sensor Then the signals are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection...

Page 24: ...switch is tripped 2 Operating the headlight illumination relay On the model for Europe the ECU causes the headlight relay 2 to output a constant ON signal provided that the main switch is ON On the m...

Page 25: ...nstream of the pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to preve...

Page 26: ...n intake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the dia phragm ope...

Page 27: ...that is integrated with the needle to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the...

Page 28: ...sition of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calcu lated data in order to determine the corresponding injection timing Based on th...

Page 29: ...s a signal and sends it to the ECU Based on this signal and the signal from the crankshaft position sensor the ECU then actuates the injector of the cylinder that is currently in order to supply fuel...

Page 30: ...oves in unison with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position...

Page 31: ...silicon diaphragm converts the intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate elec...

Page 32: ...sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atm...

Page 33: ...tration level is known When a difference in the oxygen concentration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and gen...

Page 34: ...ilt of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the motorcycle has overturned and stops the del...

Page 35: ...l it sends an injection command to the injectors Furthermore the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on...

Page 36: ...s This system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating conditio...

Page 37: ...he injector The battery voltage determines the reactive injection duration High voltage short reactive injection duration Low voltage long reactive injection duration LIST OF FUEL INJECTION COMPENSATI...

Page 38: ...n obtained through the throttle position intake air pressure and engine speed to which injection duration compensation based on the sig nals from various sensors such as the intake temperature sensor...

Page 39: ...ct fuel only once immediately upon receiving the signals from the sensors during the cranking of the engine This is called asyn chronous injection in contrast to synchronous injection which is a norma...

Page 40: ...he coolant tem perature determines the initial starting enrichment coefficient the coefficient subsequently changes in accordance with the damping factor The enrichment ratio is the highest immediatel...

Page 41: ...coolant temperature The coefficient increases with the decrease in the coolant temperature and decreases with the increase in the coolant temperature The ratio of fuel enrichment also changes with th...

Page 42: ...creases the actual enrich ment volume The enrichment volume is executed in accordance with the acceleration enrichment coefficient when the movement of the throttle position sensor has met the acceler...

Page 43: ...all the cylinders is stopped when fuel cut off control is executed thus improving fuel economy Engine speed Duration Fuel cut off control stopping fuel injection Basic injection duration Basic inject...

Page 44: ...st gas is provided in the exhaust pipe for the purpose of maximizing the performance of the three way cat alytic converter and to clean the exhaust gas at a high degree of efficiency Based on this dat...

Page 45: ...on of platinum and are converted into harmless carbon dioxide CO2 and water H2O resulting in cleaner exhaust gases The NOx is reduced by the reduction function of rhodium which converts NOx into harml...

Page 46: ...mixture is lean as indicated by excessive O2 region B Under these conflicting characteristics the system maintains the mixture within an extremely narrow range C of stoichiometric ratio 14 7 1 As a r...

Page 47: ...e basic injection volume based on the signals that are input from various sensors and regulates the duration of the current applied to the injectors Current is applied to the injectors enabling them t...

Page 48: ...through the reed valve The air cut off valve is controlled by the signals from the ECU in accordance with the combustion conditions Ordinarily the air cut off valve opens to allow the air to flow dur...

Page 49: ...air passage and flows into the reed valves of the cyl inders When the current flows to the solenoid coil in accordance with a signal from the ECU the plunger in the core becomes attracted towards the...

Page 50: ...howing the time after the error has been corrected 1 Fuel meter 2 Clock 3 Coolant temperature meter 4 TRIP meter 5 TRIP ODO meter 6 RESET button 7 SELECT button 8 Engine trouble warn ing light 9 Oil l...

Page 51: ...ts a sys tem check System normal Normal meter display Malfunction detection A fault code number appears on the clock LCD The engine trouble warning light illuminates The engine cannot be started in th...

Page 52: ...URES 1 Clock 2 TRIP meter 3 RESET button 4 SELECT button 5 Engine trouble warning light 140 150 160 170 180 130 120 220 240 260 280 200 180 160 140 MPH Km h F L H E SELECT RESET TRIP TRIP km mile km m...

Page 53: ...d place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PA...

Page 54: ...oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION Do not spin the bearing with compressed a...

Page 55: ...times 3 Check all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Ch...

Page 56: ...s are needed to remove the main axle assembly YM 01229 Gear holder This tool is needed when removing or installing the coupling gear nut YM 01230 Final drive gear lash tool This tool is needed when me...

Page 57: ...s tool is needed to hold the damper rod assembly when loosen or tighten the damper rod assembly bolt YM 01471 Frame spanner socket This tool is needed to loosen or tighten the spacer bolt YS 01880 A P...

Page 58: ...e gauge Oil pressure adaptor B These tools are needed to measure engine oil pressure Valve spring compres sor set YM 04019 Valve spring compres sor attachment YM 04108 Valve spring compressor set Valv...

Page 59: ...eeded when removing or installing the damper spring YM 04097 Valve guide remover 5 This tool is needed to remove and install the valve guide YM 04098 Valve guide installer 5 This tool is needed to ins...

Page 60: ...001 05 01 Quick Gasket This sealant is used to seal two mating surfaces e g crankcase mating sur faces YM 04140 Bearing retainer wrench This tool is needed when removing or installing the middle drive...

Page 61: ...m 55 9 in Seat height 805 mm 31 7 in Wheelbase 1 515 mm 59 6 in Minimum ground clearance 135 mm 5 3 in Minimum turning radius 3 100 mm 122 0 in Weight Wet with oil and a full fuel tank 274 kg 604 lb U...

Page 62: ...reserve 25 L 22 01 Imp qt 26 43 US qt Reserve only 5 L 4 40 Imp qt 5 29 US qt Engine oil Lubrication system Wet sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 5 C 40 F or higher...

Page 63: ...7 kPa 0 93 1 23 kg cm2 13 27 17 45 psi Valve relief pressure 4 9 kPa 0 05 kg cm2 0 70 psi Radiator core Width 360 mm 14 17 in Height 295 8 mm 11 65 in Depth 27 mm 1 06 in Coolant reservoir Capacity 0...

Page 64: ...ance 0 028 0 062 mm 0 0011 0 0024 in Intake camshaft lobe dimensions Measurement A 33 05 33 15 mm 1 3012 1 3051 in 32 05 mm 1 2618 in Measurement B 24 997 25 097 mm 0 9841 0 9881 in 23 997 mm 0 9448 i...

Page 65: ...0433 in 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve margin thickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake...

Page 66: ...39 7 mm 1 56 in 37 7 mm 1 48 in Exhaust 39 7 mm 1 56 in 37 7 mm 1 48 in Installed length valve closed Intake 33 mm 1 30 in Exhaust 33 mm 1 30 in Compressed spring force installed Intake 136 158 N 13 9...

Page 67: ...094 in Height H 5 mm 0 2 in Piston pin bore in the piston Diameter 19 004 19 015 mm 0 7482 0 7486 in 19 045 mm 0 7498 in Offset 0 5 mm 0 0197 in Offset direction Intake side Piston pins Outside diamet...

Page 68: ...2 0 0019 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink Small end inside diameter 19 005 19 018 mm 0 7482 0 7487 in Crankshaft Width A 61 6 63 2 mm 2 425 2 488 in Width B 325 1 3...

Page 69: ...length 6 44 mm 0 2535 in Push rod bending limit 0 2 mm 0 0079 in Transmission Transmission type Constant mesh 5 speed Primary reduction system Helical gear Primary reduction ratio 75 48 1 563 Seconda...

Page 70: ...2 94 kgf cm2 41 81 psi Throttle bodies Model manufacturer quantity 42EHS MIKUNI 4 Intake vacuum pressure 33 3 kPa 250 mm Hg 9 8 in Hg Throttle cable free play at the flange of the throttle grip 3 5 mm...

Page 71: ...0 5 mm 0 02 in Rear wheel Wheel type Cast wheel Rim Size 17 M C MT 5 50 Material Aluminum Wheel travel 125 mm 4 92 in Wheel runout Max radial wheel runout 1 0 mm 0 04 in Max lateral wheel runout 0 5 m...

Page 72: ...ameter thickness 298 5 mm 11 73 0 20 in Min thickness 4 5 mm 0 18 in Max deflection 0 1 mm 0 004 in Brake pad lining thickness 5 5 mm 0 22 in 0 5 mm 0 02 in Master cylinder inside diameter 14 mm 0 55...

Page 73: ...0 999 kg mm 55 96 lb in Spring stroke K2 91 135 mm 3 58 5 31 in Optional spring available No Fork oil Recommended oil Suspension oil M1 Quantity each front fork leg 670 cm3 23 6 Imp oz 22 3 US oz Leve...

Page 74: ...2 91 in 72 52 mm 2 86 in Installed length 65 4 mm 2 57 in Spring rate K1 71 6 N mm 7 30 kg mm 408 86 lb in Spring stroke K1 0 31 3 mm 0 1 23 in Spring rate K2 102 N mm 10 4 kg mm 582 45 lb in Spring s...

Page 75: ...system System type AC magneto Model manufacturer TLNZ79 DENSO Nominal output 14 V 490 W at 5 000 r min Stator coil resistance color 0 15 0 23 W W Voltage regulator Regulator type Semiconductor short...

Page 76: ...0 96 in 23 5 mm 0 93 in Mica undercut 1 5 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 A Coil resistance 4 18 4 62 Horn Horn type Plane Model manufacturer quantity YF 12...

Page 77: ...85 0 F Valve lift full open 8 mm 0 31 in Intake air temperature sensor Model manufacturer 25978 MITSUBISHI Resistance 5 4 6 6 at 80 C 176 F Coolant temperature sender Model manufacturer 8CC MITSUBISHI...

Page 78: ...specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0...

Page 79: ...2 LT Stator assembly lead holder Screw M6 1 6 0 6 4 3 Pickup coil rotor cover Bolt M6 8 12 1 2 8 7 Ignition timing check bolt M8 1 15 1 5 11 Crankshaft position sensor Bolt M5 2 4 0 4 2 9 LT Pickup c...

Page 80: ...1 2 8 7 E Crankcase Bolt M6 17 10 1 0 7 2 E Rear balancer cover Bolt M6 4 12 1 2 8 7 Balancer lever Bolt M8 2 14 1 4 10 Balancer shaft pinch bolt M6 2 10 1 0 7 2 Plate Torx screw M6 2 12 1 2 8 7 LT C...

Page 81: ...en the crankcase bolts further to reach the specified angle 120 in the proper tightening sequence 3 Tighten the connecting rod nuts to 20 Nm 2 0 m kg 14 ft lb and then tighten the connecting rod nuts...

Page 82: ...2 22 SPEC TIGHTENING TORQUES Cylinder head tightening sequence Crankcase tightening sequence...

Page 83: ...nut M18 125 12 5 90 Rear wheel axle pinch bolt M8 16 1 6 11 Brake torque rod M8 16 1 6 11 Rear brake caliper retaining bolt M10 27 2 7 19 Brake hose union bolt M10 30 3 0 22 Front brake master cylinde...

Page 84: ...t rider footrest bracket and engine M10 49 4 9 35 Left rider footrest bracket sidestand bracket and frame M10 63 6 3 45 Ring gear bearing housing and final drive housing M10 40 4 0 29 Ring gear bearin...

Page 85: ...s intake and exhaust M Valve stem ends intake and exhaust E Water pump impeller shaft E Oil pump rotors inner and outer E Oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Sta...

Page 86: ...er mating surface Sealant Cylinder head cover Sealant Crankcase mating surface Sealant Clutch cover crankcase mating surface Sealant Generator cover crankcase mating surface Sealant Pickup coil rotor...

Page 87: ...nd pivoting point and sliding surface LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivot bolt and contact surface LS Clutch lever pivot bol...

Page 88: ...2 28 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil pump 3 Oil pipe 4 Relief valve 5 Oil filter cartridge 6 Main axle LUBRICATION POINTS AND LUBRICANT TYPES...

Page 89: ...2 29 SPEC 1 Crankshaft 2 Main axle 3 Drive axle OIL FLOW DIAGRAMS...

Page 90: ...2 30 SPEC 1 Oil nozzle 2 Main gallery bolt 3 Crankshaft OIL FLOW DIAGRAMS...

Page 91: ...2 31 SPEC 1 Main axle 2 Drive axle 3 Oil delivery pipe OIL FLOW DIAGRAMS...

Page 92: ...2 32 SPEC 1 Exhaust camshaft 2 Oil check bolt 3 Intake camshaft OIL FLOW DIAGRAMS...

Page 93: ...2 33 SPEC 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil pump 5 Oil strainer 6 Oil pipe OIL FLOW DIAGRAMS...

Page 94: ...2 34 SPEC 1 Crank pin 2 Crankshaft OIL FLOW DIAGRAMS...

Page 95: ...2 35 SPEC 1 Rear balancer 2 Oil delivery pipe 3 Crankshaft 4 Front balancer 5 Crank pin OIL FLOW DIAGRAMS...

Page 96: ...2 36 SPEC 1 Oil strainer 2 Oil delivery pipe 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil pan 8 Oil pipe 9 Oil pump OIL FLOW DIAGRAMS...

Page 97: ...2 37 SPEC 1 Main axle 2 Drive axle 3 Middle drive shaft OIL FLOW DIAGRAMS...

Page 98: ...2 38 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator COOLING SYSTEM DIAGRAMS...

Page 99: ...2 39 SPEC 1 Water jacket joint 2 Oil cooler COOLING SYSTEM DIAGRAMS...

Page 100: ...2 40 SPEC 1 Thermostat assembly 2 Coolant reservoir 3 Radiator 4 Oil cooler COOLING SYSTEM DIAGRAMS...

Page 101: ...2 41 SPEC 1 Coolant reservoir 2 Radiator 3 Water pump COOLING SYSTEM DIAGRAMS...

Page 102: ...ble 2 Brake cable 3 Clutch cable 4 Main switch lead 5 Headlight lead 6 Fuse box 7 Thermostat assembly breather hose 8 Coolant reservoir hose 9 Hazard switch 0 Rectifier regulator A Plate B Plunger con...

Page 103: ...servoir hose and thermostat assembly breather hose through the left slit of the plate To the thermostat housing After passing the coolant reservoir hose through the two hose guides behind the plate pa...

Page 104: ...ain fuse 8 Front turn signal lead 9 Spark plug lead 4 0 Spark plug lead 1 A Ignition coil lead 1 4 B Ignition coil 1 4 C Coolant reservoir D Coolant reservoir breather hose E Coolant reservoir hose F...

Page 105: ...nnector so that the ignition coil lead can be turned outward Support the coolant reservoir breather hose with the hose holder attached to the coolant reser voir Pass the brake cable through the brake...

Page 106: ...of the coolant reservoir hose should extend at least 50 mm 2 0 in from the hose guide Fasten the spark plug lead 1 and 4 at the number tag Pass the wire harness spark plug leads 1 2 3 and 4 through t...

Page 107: ...2 47 SPEC CABLE ROUTING 1 Tail brake light lead...

Page 108: ...fier regulator 5 Clutch cable 6 Fuel tank overflow hose 7 Fuel tank breather hose 8 Stator coil lead 9 Sidestand switch 0 Sidestand switch lead A Oil level switch lead B Brake cable C Coolant reservoi...

Page 109: ...e frame Clamp the wire harness with the plastic band attached to the frame To the fuel tank Pass the stator coil lead at the fork of the wire harness Attach the clutch cable to the frame using the clu...

Page 110: ...ten the tail brake light lead with a plastic band to the frame Pass the tail brake light lead between the rear cover and frame Pass the wire harness on the inside of the seat lock cable Support the wi...

Page 111: ...ad 4 Headlight lead 5 Main switch lead 6 Throttle cable 7 Right handlebar switch lead 8 T bar 9 Spark plug lead 3 0 Spark plug lead 2 A Spark plug lead 1 B Spark plug lead 4 C Cable guide D Throttle p...

Page 112: ...le cables through the hole on the right side of the frame To the lower right slit of the plate To the cylinder identification sensor To the fuel tank Pass the cylinder identification sensor lead throu...

Page 113: ...eads 1 2 3 and 4 and the wire harness head light lead main switch lead right handlebar switch lead and left handlebar switch lead Install the thermostat heat protector throttle cables spark plug leads...

Page 114: ...2 54 SPEC 1 Engine stop switch 2 Starting circuit cut off relay 3 Atmospheric pressure sensor 4 CYCLELOCK coupler 5 Seat lock cable CABLE ROUTING...

Page 115: ...attached to the frame Pass the CYCLELOCK coupler through the inside of the storage box of the U lock Pass the CYCLELOCK coupler through the lead guide Pass the pressure sensor lead and engine stop swi...

Page 116: ...4 Canister charge hose 5 Canister purge hose 6 Rollover valve 7 Canister To the left front of the fuel tank To the left rear of the fuel tank To the throttle bodies Align the white paint marks on the...

Page 117: ...nce Check and adjust valve clearance when engine is cold Every 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Cr...

Page 118: ...l leakage Repair if necessary 12 Steering bearings Check bearing assembly for looseness Moderately repack with lithium soap based grease every 12 000 mi 19 000 km or 18 months Repack 13 Brake and clut...

Page 119: ...brake or clutch master cylinders caliper cylinders or clutch release cylin der always change the fluid Regularly check the brake and clutch fluid levels and fill the reser voirs as required Every two...

Page 120: ...S AND FUEL TANK EAS00039 SEATS AND FUEL TANK SEATS Order Job Part Q ty Remarks Removing the seats Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 For installation reverse the re...

Page 121: ...nel left and right 1 1 2 Bolt 2 3 Nut 1 4 Fuel sender coupler 1 5 Fuel pump coupler 1 6 Fuel tank overflow hose 1 7 Fuel tank breather hose 1 8 Hose holder 1 9 Fuel hose holder 2 10 Fuel hose 1 Refer...

Page 122: ...Removing the T bar Remove the parts in the order listed Rider seat fuel tank Refer to SEATS AND FUEL TANK 1 Left rubber cover 1 2 Right rubber cover 1 3 T bar 1 4 Rubber sheet 1 For installation reve...

Page 123: ...uel remain ing in it NOTE Before removing the hoses place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal lation surface...

Page 124: ...oss pattern and to the specified torque FWD T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose holders CAUTION When installing the fuel hose make sure that it is secure...

Page 125: ...el tank Refer to SEATS AND FUEL TANK Side covers left and right Refer to COWLINGS AND COVERS 1 Air shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Lean angle cut off switch 1 5 Tray 1 6 Fu...

Page 126: ...rder Job Part Q ty Remarks 10 Air induction system hose 5 1 Disconnect 11 Clamp screw 4 Loosen 12 Air filter case 1 13 Air filter case breather hose 1 For installation reverse the removal procedure AI...

Page 127: ...AND FUEL TANK 1 Left side cowling 1 2 Right side cowling 1 3 Front bottom cowling 1 4 Front turn signal connector left 2 5 Front turn signal connector right 2 6 Left inner panel front cowling 1 7 Fus...

Page 128: ...front cowling assembly Remove the parts in the order listed 1 Windshield outer bracket 1 2 Windshield 1 3 Grommet 7 4 Windshield inner bracket 1 5 Rear view mirror left and right 2 6 Panel 1 7 Front c...

Page 129: ...13 CHK ADJ 1 Order Job Part Q ty Remarks Removing the headlight assembly Remove the parts in the order listed 1 Headlight assembly 1 For installation reverse the removal procedure COWLINGS AND COVERS...

Page 130: ...the parts in the order listed 1 Windshield drive unit 1 2 Windshield drive unit coupler 2 3 Meter assembly 1 4 Meter assembly coupler 1 5 Headlight relay 1 1 6 Headlight relay 2 1 7 Fuel injection sys...

Page 131: ...Order Job Part Q ty Remarks Removing the covers Remove the parts in the order listed Seats Refer to SEATS AND FUEL TANK 1 Left side cover 1 2 Right side cover 1 3 Rear carrier 1 4 Rear cover 1 For ins...

Page 132: ...be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK side cowlings front cowling a...

Page 133: ...d when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve...

Page 134: ...wise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise 7 Remove intake camshaft caps exhaust camshaft caps timing chain from the camshaft sprockets intake ca...

Page 135: ...ded in order to reach the closest equiva lent to the original c Round off the original valve pad number according to the following table EXAMPLE Original valve pad number 148 thickness 1 48 mm Rounded...

Page 136: ...d intake camshafts timing chain and camshaft caps NOTE Refer to INSTALLING THE CAMSHAFTS CAMSHAFTS in chapter 5 Lubricate the camshafts camshaft lobes and camshaft journals First install the exhaust c...

Page 137: ...28 1 32 230 235 240 1 33 1 37 235 240 1 38 1 42 240 MEASURED CLEARANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 0...

Page 138: ...roperly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand 2 Remove rider seat fuel tank T bar Refer to SEATS AN...

Page 139: ...the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION Do not use the throttle valve adjusting screws to adjust the throt...

Page 140: ...ee play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in 12 Remove engine tachometer vacuum gauge 13 Remove fuel tank 14...

Page 141: ...minutes 2 Remove fuel tank side panels left and right fuel tank front mounting bolts 3 Lift up the front of the fuel tank 4 Attach inductive tachometer onto the spark plug lead of cylinder 1 5 Measure...

Page 142: ...nt mounting bolts fuel tank side panels left and right Refer to SEATS AND FUEL TANK EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idli...

Page 143: ...a or b until the specified throttle cable free play is obtained e Tighten the locknuts NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the...

Page 144: ...seat Refer to SEATS AND FUEL TANK EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove rider seat fuel tank T bar Refer to SEATS AND FUEL TANK 2 Disconn...

Page 145: ...a wire gauge Out of specification Regap 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install T bar fuel tank rider sea...

Page 146: ...cylinder 1 3 Install fuel tank Refer to SEATS AND FUEL TANK 4 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check...

Page 147: ...to all of the cylinders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Star...

Page 148: ...ifference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 14 22 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces...

Page 149: ...r Same as without oil Piston ring s valves cylinder head gasket or pis ton possibly defec tive Repair 10 Install spark plug 11 Connect spark plug cap 12 Install T bar fuel tank rider seat T R 13 Nm 1...

Page 150: ...clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase NOTE _ API Service SE SF and SG type or equivalent e g SF SE SF SE CC SF SE SD Before...

Page 151: ...laced perform the following procedure a Remove the left side cowling Refer to COWLINGS AND COVERS b Remove the oil filter cartridge 1 with an oil filter wrench 2 c Lubricate the O ring 3 of the new oi...

Page 152: ...ed engine oil 9 Install engine oil filler cap 10 Start the engine warm it up for several min utes and then turn it off Quantity Total amount 4 9 L 4 31 Imp qt 5 18 US qt Without oil filter cartridge r...

Page 153: ...IL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification T R Oil gallery bolt 20 Nm 2 0 m kg 14 ft lb...

Page 154: ...stall main gallery bolt Pressure gauge 90890 03153 Oil pressure adapter B 90890 03124 Engine oil pressure 30 kPa 0 30 kg cm2 4 27 psi Engine speed Approx 1 000 1 100 r min Engine oil temperature 73 C...

Page 155: ...dial with the arrow mark 2 on the clutch lever holder WARNING After adjusting the clutch lever position make sure the pin on the clutch lever holder is firmly inserted in the hole in the adjusting dia...

Page 156: ...eful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch fluid may damage painted surfac...

Page 157: ...the hose have disappeared 1 Bleed hydraulic clutch system a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir diaphragm c Connect a clear plastic hose...

Page 158: ...ng the hydraulic clutch system check the clutch operation EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove seats Refer to SEATS AND FUEL TANK left side cover Refer to COWLINGS AND COVERS 2 Remove air...

Page 159: ...ce and possible overheat ing NOTE When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 7 Install air shroud 8 In...

Page 160: ...efer to SEATS AND FUEL TANK EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove rider seat fuel tank Refer to SEATS AND FUEL TANK air filter case Refer to AIR FILTER CASE 2 Check crankcase breather...

Page 161: ...Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 3 Check tightening torque 4 Install side cowlings Refer to COWLINGS AND COVERS T R Exhaust pipe assembly and bra...

Page 162: ...mum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec...

Page 163: ...ing assembly Refer to COWLINGS AND COVERS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket joint 6 Cracks damage Replace Re...

Page 164: ...he radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or...

Page 165: ...es Mixing ratio 1 1 antifreeze water Quantity Total amount 3 2 L 2 82 Imp qt 3 38 US qt Coolant reservoir capacity 0 485 L 0 43 Imp qt 0 51 US qt From minimum to maximum level mark 0 15 L 0 13 Imp qt...

Page 166: ...wash them with water Do not mix different types of antifreeze 12 Install radiator cap 13 Remove coolant reservoir cap cover 1 coolant reservoir cap 14 Fill coolant reservoir with the recommended cool...

Page 167: ...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 sys tem lever can indicate the presence of air in the brake syste...

Page 168: ...1 to specification WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake...

Page 169: ...luid level Below the minimum level mark a Add the recommended brake fluid to the proper level Front brake Rear brake WARNING Use only the designated brake fluid Other brake fluids may cause the rubber...

Page 170: ...procedure applies to all of the brake pads 1 Operate the brake 2 Check front brake pad Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in ch...

Page 171: ...ime c Install the right footrest bracket bolts Direction a Brake light comes on sooner Direction b Brake light comes on later T R Right footrest bracket bolt 28 Nm 2 8 m kg 20 ft lb EAS00131 CHECKING...

Page 172: ...o enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding proce...

Page 173: ...ten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic...

Page 174: ...e final drive housing oil filler bolt 1 3 Check final drive oil level The final drive oil level should be to the bot tom brim 1 of the filler hole Below the bottom brim Add the recom mended final driv...

Page 175: ...fer to CHECKING THE FINAL DRIVE OIL LEVEL Quantity 0 2 L 0 18 Imp qt 0 21 US qt EAS00147 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the motorcycle on a level surface WARNING Securely support the...

Page 176: ...turn and then tighten it to specification with a steering nut wrench WARNING Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the...

Page 177: ...ebars washer steering stem nut 7 Tighten upper bracket pinch bolts T R 115 Nm 11 5 m kg 85 ft lb T R 34 Nm 3 4 m kg 24 ft lb EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface...

Page 178: ...ger of it falling over Spring preload CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the a...

Page 179: ...17 clicks out Standard 12 clicks out Maximum 1 click out Compression damping CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust compression damping a Turn the adjusting scr...

Page 180: ...direction a or b b Adjust the adjusting lever to HARD or SOFT Position a Spring preload is increased suspension is harder Position b Spring preload is decreased suspension is softer Rebound damping C...

Page 181: ...nsion must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an a...

Page 182: ...d pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and repla...

Page 183: ...inting in the direction of wheel rotation Align the mark 5 with the valve installation point Manufacturer Model Size METZELER MEZ4J FRONT 120 70 ZR17 M C 58W BRIDGESTONE BT020F N 120 70 ZR17 M C 58W M...

Page 184: ...heath Damage Replace 2 Check cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recom...

Page 185: ...STAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting poi...

Page 186: ...te as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTER...

Page 187: ...ket tester to the battery termi nals NOTE The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No...

Page 188: ...re connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full conta...

Page 189: ...rd charg ing amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable t...

Page 190: ...hes 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Thi...

Page 191: ...y terminals 10 Install right inner panel front cowling Refer to COWLINGS AND COVERS Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fu...

Page 192: ...f the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Items Amperage rating Q ty Main fuse 50 A 1 Headlight fuse 25 A 1 Radiator fan motor fuse 15...

Page 193: ...ibly cause a fire 4 Install front right inner panel front cowling right inner panel front cowling left inner panel front cowling Refer to COWLINGS AND COVERS EAS00183 REPLACING THE HEADLIGHT BULBS The...

Page 194: ...nd 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 6 Attach headlight bulb holder 7 Install he...

Page 195: ...zontally a Turn the adjusting screw 1 in direction a or b Left headlight Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headligh...

Page 196: ...3 80 CHK ADJ ADJUSTING THE HEADLIGHT BEAMS...

Page 197: ...ce the motorcycle on a suitable stand so that the front wheel is elevated 1 Brake caliper left and right 2 Refer to REMOVING INSTALLING THE FRONT WHEEL 2 Wheel axle pinch bolt 1 Loosen 3 Front wheel a...

Page 198: ...WHEEL AND BRAKE DISCS EAS00518 Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disasse...

Page 199: ...ove left brake caliper right brake caliper NOTE Do not squeeze the brake lever when remov ing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front w...

Page 200: ...seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c...

Page 201: ...ing the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the...

Page 202: ...fication f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE EAS00545 INSTALLING THE FRONT WHEEL The follow...

Page 203: ...nstalled 1 Remove balancing weight s 2 Find front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X mark at the b...

Page 204: ...rn 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 balance...

Page 205: ...s in the order listed NOTE Place the motorcycle on a suitable stand so that the rear wheel is elevated 1 Brake torque rod nut bolt 1 1 Refer to INSTALLING THE REAR WHEEL 2 Wheel axle nut 1 3 Wheel axl...

Page 206: ...rear wheel Remove the parts in the order listed 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 2 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Sp...

Page 207: ...levated 2 Remove brake caliper bracket NOTE Do not depress the brake pedal when remov ing the brake caliper bracket with brake cali per 3 Remove rear wheel NOTE Move the rear wheel to the right to sep...

Page 208: ...2 Tighten brake torque rod nut wheel axle nut wheel axle pinch bolt T R 30 Nm 3 0 m kg 22 ft lb T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb EAS00575 ADJUSTING THE REAR WHEEL STATIC BALAN...

Page 209: ...ont brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake hose holder bolt 1 2 Brake caliper bolt 2 3 Brake pad clip 2 4 Brake pad...

Page 210: ...AS00578 REAR BRAKE PADS Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad 2 3 Brake pad shim 2 4 Bleed screw 1 For installati...

Page 211: ...y clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming...

Page 212: ...install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the b...

Page 213: ...evel Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583...

Page 214: ...d a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pis...

Page 215: ...the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake s...

Page 216: ...oving the front brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake maste...

Page 217: ...bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder holder 1 10 Brake master cylinder 1 11 Front...

Page 218: ...Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For as...

Page 219: ...n the order listed Side cover right Refer to COWLINGS AND COVERS in chapter 3 Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphra...

Page 220: ...Part Q ty Remarks 9 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING THE REAR BRAKE MASTER CYLINDER 10 Copper washer 2 11 Brake hose 1 Disconnect 12 Cotter pin 1 13 Pin 1 14 Brake master cylinder 1 For...

Page 221: ...Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder 1...

Page 222: ...em 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE RE...

Page 223: ...id delivery passages brake master cylinder body Obstruction Blow out with compressed air Front Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace Front Rear 3 Check rear brake flui...

Page 224: ...ponents 1 Install brake master cylinder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a in the right...

Page 225: ...uids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a har...

Page 226: ...SYSTEM in chapter 3 EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers 1 brake hose 2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle ope...

Page 227: ...ervoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any sp...

Page 228: ...4 32 CHAS FRONT AND REAR BRAKES 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3...

Page 229: ...order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Brake hose holder bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS...

Page 230: ...rder listed 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 brake pad shim 2 2 5 Brake caliper piston 4 Refer...

Page 231: ...rder listed Brake fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Retaining bolt 2 Loosen 5 Brake torqu...

Page 232: ...r Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad brake pad shim 2 2 3 Brake pad spring 2 4 Rear brake caliper bracket 1 5 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BR...

Page 233: ...ke hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blo...

Page 234: ...rake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper piston 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out th...

Page 235: ...brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals Front Rear Recommende...

Page 236: ...ll cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copp...

Page 237: ...e and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When...

Page 238: ...ULIC BRAKE SYSTEM in chapter 3 EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new b...

Page 239: ...union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose onto the brake caliper make sure the brak...

Page 240: ...ading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor...

Page 241: ...4 45 CHAS FRONT AND REAR BRAKES 9 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3...

Page 242: ...emoving the clutch master cylin der Remove the parts in the order listed Clutch fluid Drain 1 Clutch master reservoir cap 1 2 Clutch master reservoir diaphram holder 1 3 Clutch master reservoir diaphr...

Page 243: ...INSTALLING THE CLUTCH MASTER CYLINDER 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 Refer to ASSEMBLING AND INSTALLING THE CLUTCH MASTER C...

Page 244: ...the clutch master cylinder Remove the parts in the order listed 1 Clutch master cylinder push rod 1 2 Dust seal 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder 1 For...

Page 245: ...components Clutch fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serio...

Page 246: ...eplace the clutch mas ter cylinder clutch fluid delivery passage clutch master cylinder body Obstruction Blow out with compressed air 2 Check clutch master cylinder 1 clutch master cylinder kit 2 Rust...

Page 247: ...lutch fluid Brake fluid DOT 4 1 Install clutch master cylinder 1 NOTE Install the clutch master cylinder holder with the UP mark facing up Align the end of the clutch master cylinder holder with the p...

Page 248: ...luid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu...

Page 249: ...fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 6 Check clutch lever operation Soft or spongy fee...

Page 250: ...Remove the parts in the order listed Clutch fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutc...

Page 251: ...Remove the parts in the order listed 1 Clutch release cylinder piston 1 Refer to DISASSEMBLING THE CLUTCH RELEASE CYLINDER 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4...

Page 252: ...lly 2 Remove clutch release cylinder piston 1 clutch release cylinder spring 2 clutch release cylinder piston seal 3 a Blow compressed air into the clutch hose joint opening a to force out the piston...

Page 253: ...ch release cylinder piston 2 Rust scratches wear Replace the clutch release cylinder and clutch release cylinder piston as a set EAS00315 ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER 1 Instal...

Page 254: ...erformance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch...

Page 255: ...4 59 CHAS 5 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 HYDRAULIC CLUTCH...

Page 256: ...he front fork legs Front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Collar 2 3 Collar 2 4 Upper bracket pinch bolt 1...

Page 257: ...rder listed The following procedure applies to both of the front fork legs 1 Cap bolt O ring 1 1 Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 2 Damper adjusting rod 1 3 Nut 1 4 Spacer 1 5 Was...

Page 258: ...DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS C Inner tube 1 D Oil seal 1 Refer to ASSEMBLING THE FRONT FORK LEGS E Seal spacer 1 F Outer tube bushing 1 G Inner tube bushing 1 H Oil flow stopper 1 I O...

Page 259: ...suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolts 3 WARNING Before loosening the upper and lower bracket pinch bolts support t...

Page 260: ...amper rod assembly bolt While holding the damper rod with the damper rod holder 2 loosen the damper rod assembly bolt 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the br...

Page 261: ...free length a Out of specification Replace Spring free length 261 mm 10 28 in 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stoppe...

Page 262: ...en assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure all of the components ar...

Page 263: ...kg 25 ft lb 4 Install outer tube bushing 1 with the fork seal installer 2 Fork seal installer YM 01442 New 5 Install seal spacer oil seal 1 with the fork seal driver CAUTION Make sure the numbered sid...

Page 264: ...the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork...

Page 265: ...top of the inner tube with the inner tube fully compressed and without the spring 100 mm 3 94 in 14 Install nut 1 damper adjusting rod 2 cap bolt 3 a Install the nut 1 and finger tighten it b Install...

Page 266: ...Make sure that the inner tube end is flush with the top of the upper bracket Temporarily tighten the upper and lower bracket pinch bolts WARNING Make sure the brake hoses are routed prop erly 2 Tight...

Page 267: ...ont fender Install the collar 2 from the inside of the front fender When installing the front fender make sure that there is no dirt between the front fender and front fork T R 6 Nm 0 6 m kg 4 3 ft lb...

Page 268: ...ebar Remove the parts in the order listed 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Clutch master cylinder 1 4 Left handlebar...

Page 269: ...Front brake light switch connector 2 Disconnect 2 Brake master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Brake master cylinder 1 4 Grip end 1 5 Throttle cable housing 1 6 Throttl...

Page 270: ...ed air between the left handle bar and the handlebar grip and gradually push the grip off the handlebar 3 Remove throttle cable housing 1 throttle grip 2 NOTE While removing the throttle cable housing...

Page 271: ...in the right handlebar 3 Install throttle grip 1 throttle cable housing 2 throttle cables grip end NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and insta...

Page 272: ...dlebar grip grip end a Apply a thin coat of rubber adhesive onto the left end of the left handlebar b Slide the handlebar grip over the left end of the left handlebar c Wipe off any excess rubber adhe...

Page 273: ...the slit in the clutch master cylinder holder with the punch mark a in the left han dlebar T R 10 Nm 1 0 m kg 7 2 ft lb 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PL...

Page 274: ...s in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebars Refer to HANDLEBARS 1 Lead guide 2 2 Main switch coupler 2 Disconnect Refer to INS...

Page 275: ...LOWER BRACKET and INSTALLING THE STEERING HEAD 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Bearing cover 1 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearin...

Page 276: ...1 with the special tool 2 WARNING Securely support the lower bracket so that there is no danger of it falling Spanner wrench YU 33975 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races...

Page 277: ...bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EA...

Page 278: ...racket steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK NOTE Temporarily tighten the lower and upper bracket pinch bolts 5 Tighten steerin...

Page 279: ...r Job Part Q ty Remarks Removing the rear shock absorber assembly and relay arm Remove the parts in the order listed Rear wheel Refer to REAR WHEEL AND BRAKE DISC Mufflers exhaust pipe Refer to ENGINE...

Page 280: ...64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib Order Job Part Q ty Remarks 9 Relay arm 1 10 Collar 1 11 Collar...

Page 281: ...use an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping performance EAS00688 DISPOSING OF A REA...

Page 282: ...swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check rear shock absorber rod Bends damage Replac...

Page 283: ...s 2 Install bearing 1 2 to the relay arm Recommended lubricant Lithium soap base grease Installed depth a 4 0 mm 0 16 in Installed depth b 4 5 mm 0 18 in EAS00698 INSTALLING THE REAR SHOCK ABSORBER AS...

Page 284: ...chapter 5 Rear wheel Refer to REAR WHEEL AND BRAKE DISC Final drive assembly universal joint Refer to SHAFT DRIVE Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1 Ri...

Page 285: ...s 9 Oil seal 2 10 Bearing 2 Refer to INSTALLING THE SWINGARM 11 Spacer 1 12 Oil seal 1 13 Bushing 1 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Spacer 1 18 Bearing 1 Refer to INSTALLING THE SWINGARM Fo...

Page 286: ...nut b Measure the swingarm side play by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bushing and bear ings d Check the swingarm vertica...

Page 287: ...ot shaft spacers bushing bearings Recommended cleaning solvent Kerosene 4 Check spacers bushing oil seals Damage wear Replace bearings Damage pitting Replace EAS00712 INSTALLING THE SWINGARM 1 Lubrica...

Page 288: ...4 92 CHAS 3 Install bearing 1 to the swingarm Installed depth a 4 0 mm 0 16 in SWINGARM...

Page 289: ...rky movement during acceleration deceleration or sustained speeds not to be confused with engine surg ing or transmission related movements 2 A rolling rumble noticeable at low speeds a high pitched w...

Page 290: ...tion Diagnosis Possible incorrect reassembly or too little gear backlash WARNING Insufficient gear backlash is extremely destructive to the gear teeth If a test ride following reassembly indicates the...

Page 291: ...d YES Replace the wheel bearing Refer to FRONT WHEEL AND BRAKE DISCS NO Place the motorcycle on a suitable stand so that the rear wheel is elevated and then spin the rear wheel Is the wheel bearing da...

Page 292: ...Check shaft drive housing for oil leaks a Thoroughly clean the entire motorcycle and then completely dry it b Apply a leak locating compound or dry pow der spray to the shaft drive c Test ride the mo...

Page 293: ...overtighten the bolt c Install the final drive gear lash tool 2 and dial gauge 3 a Dial gauge plunger contact point 60 mm 2 36 in d Gently rotate the gear coupling from engagement to engagement e Reco...

Page 294: ...t the suitable shim s and thrust washer with the following chart b If it is necessary to increase the ring gear backlash by more than 0 2 mm reduce the thrust washer thickness by 0 2 mm for every 0 2...

Page 295: ...arance a Out of specification Adjust 1 Stopper bolt 2 Ring gear 3 Install ring gear bearing housing along with the ring gear Ring gear to stopper bolt clear ance 0 30 0 60 mm 0 01 0 02 in EAS00722 ADJ...

Page 296: ...AUTION The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Apply LOCTITE onto the stopper bolt 4 Measure ring gear to stopper bolt clearance NOTE If the ring g...

Page 297: ...g the final drive assembly Remove the parts in the order listed Final gear oil Drain Rear wheel Refer to REAR WHEEL AND BRAKE DISC 1 Final drive assembly 1 Refer to INSTALLING THE UNIVERSAL JOINT AND...

Page 298: ...order listed Final drive assembly 1 Shift arm 1 Refer to INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY 2 Left footrest bracket 1 Refer to REMOVING THE LEFT FOOTREST BRACKET 3 Dust cover 1 4...

Page 299: ...arts in the order listed 1 Circlip 2 2 Oil seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing oil seal 1 1 6 Dust cover 1 Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 Ring...

Page 300: ...EMBLY and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR C Gear coupling 1 D Bearing retainer oil seal 1 1 Left hand threads E Final drive pinion gear bearing 1 1 F Final drive pinion gear shim s...

Page 301: ...THE FINAL DRIVE ASSEMBLY 1 Remove ring gear bearing housing nuts ring gear bearing housing bolts NOTE Working in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos...

Page 302: ...new bearings CAUTION The final drive pinion gear should only be removed if ring gear replacement is neces sary NOTE Lightly tap on the end of the final drive pinion gear with a soft hammer Piston bea...

Page 303: ...ifficult procedure and is rarely neces sary 4 Install bearing a Heat the final gear case to approximately 150 C 302 F b Install the bearing outer races with a socket or appropriate tool that matches t...

Page 304: ...e final drive housing and the drive pinion gear 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b To find final drive pinion gear shim thickness A use the following formula Where a a n...

Page 305: ...mm 0 02 in final drive pinion gear shim Final drive pinion gear shims Thickness mm 0 30 0 40 0 50 Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 c To find ring gear shim thickness B use the follo...

Page 306: ...culated ring gear shim thick ness is 0 51 mm 0 02 in Shim sizes are supplied in the following thick nesses Since the ring gear shims are only available in 0 10 mm 0 004 in increments round off the hun...

Page 307: ...n bearing retainer remover YM 04050 T R 110 Nm 11 0 m kg 80 ft lb 3 Install gear coupling 1 nut 2 with the coupling gear holder 3 CAUTION Apply LOCTITE to the nut 4 Lock the threads with a drift punch...

Page 308: ...sti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bearing housing along with the ring gear g If the ring gear to thrust washer clearance is out of...

Page 309: ...ft splines with the driven yoke of the universal joint 3 Tighten final drive assembly nuts Recommended lubricant Lithium soap base grease T R 42 Nm 4 2 m kg 30 ft lb 4 Install shift arm 1 NOTE Align t...

Page 310: ...isted Seats fuel tank T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in cha...

Page 311: ...rottle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 Air cut off valve assembly hoses reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Thermostat assembly Refer to THERMOSTAT in chapter 6 E...

Page 312: ...switch coupler 1 Disconnect 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect 6 Stator assembly coupler 1 Disconnect 7 Oil level sensor connector 1 Disconnect 8 Crankshaft position sensor...

Page 313: ...m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE Place a sui...

Page 314: ...T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Ord...

Page 315: ...pinch bolt A NOTE Tighten the spacer bolt 2 to specification with a frame spanner socket B When tightened the spacer bolt 2 should be flat against the engine surface Frame spanner socket YM 01471 T R...

Page 316: ...lb 5 Temporarily tighten the bolt engine bracket 1 and frame 1 and bolts engine bracket 1 and engine 2 NOTE When temporarily tightened the bolts 1 2 should be flat against the engine and frame surface...

Page 317: ...cylinder head cover Remove the parts in the order listed Reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Spark plug 4 2 Cylinde...

Page 318: ...EM in chapter 7 Pickup coil rotor cover Refer to PICKUP COIL ROTOR 1 Timing chain tensioner 1 Refer to REMOVING INSTALLING THE CAMSHAFTS 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exh...

Page 319: ...5 10 ENG Order Job Part Q ty Remarks 10 Timing chain guide exhaust side 1 11 Pin 1 12 Timing chain guide intake side 1 For installation reverse the removal procedure CAMSHAFTS...

Page 320: ...n the pickup coil rotor with the crankcase mating surface b NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Loosen cap bolt 1 3 Remove timing...

Page 321: ...mensions a and b Out of specification Replace the cam shaft Minimum cam lobe dimensions Intake camshaft a 32 05 mm 1 2618 in b 23 997 mm 0 9448 in Exhaust camshaft a 32 95 mm 1 2972 in b 24 897 mm 0 9...

Page 322: ...nal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journa...

Page 323: ...ing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS00217 INSTALLING THE CAMSHAFTS 1 Install exhaust cams...

Page 324: ...the timing chain start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side Make sure the marks e on the timing chain sprockets are parallel with th...

Page 325: ...T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE Mak...

Page 326: ...turns clockwise 7 Check T mark a Make sure the T mark a on the pickup coil rotor is aligned with the crankcase mat ing surface b camshaft holes c Make sure the holes c in the cylinder 4 cam are aligne...

Page 327: ...Apply bond T1541 1 onto the mating sur faces of the cylinder head cover and cylinder head cover gasket Apply bond YGK8624 C1 2 onto the mating surfaces of the cylinder head cover gasket and cylinder h...

Page 328: ...Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Radiator Refer to RADIATOR in chapter 6 Exhaust pipe assembly Refer to ENGINE Camshafts Refer to CAMSHAFTS 1 Cylin...

Page 329: ...Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Elim...

Page 330: ...d NOTE Pass the timing chain through the timing chain cavity 3 Tighten cylinder head bolts M10 1 NOTE Do not reuse the cylinder head bolts The tightening procedure of the cylinder head bolts is angle...

Page 331: ...the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench...

Page 332: ...valves and valve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 16 Refer to REMOVING INSTALLING THE VALVES 2 Valve pad 16 3 Valve cotter 32 4 Upper s...

Page 333: ...roperly seal 1 Remove valve lifter 1 valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve for leakage L...

Page 334: ...ment 3 Valve spring compressor set YM 03153 Attachment YM 04108 4 Remove upper spring seat 1 valve spring 2 valve 3 oil seal 4 lower spring seat 5 NOTE Identify the position of each part very carefull...

Page 335: ...valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1...

Page 336: ...thickness Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in 6 Measure valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the...

Page 337: ...and valve face contacted one another the blueing will have been removed Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 06...

Page 338: ...ff all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the va...

Page 339: ...ing force installed 13 9 16 1 kg at 33 mm 30 6 35 5 lb at 1 30 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Maximum valve spring tilt 1 7 mm 0 07 in EAS00242 CHECKING...

Page 340: ...an oil stone 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install lower spring seat 1 oil seal 2 valve 3 valve spring 4 upper spr...

Page 341: ...valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve 6 Lubricate valve pad valve lifter with t...

Page 342: ...r listed Fuel tank seats T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE...

Page 343: ...starter clutch idle gear 1 7 Generator rotor 1 Refer to REMOVING INSTALLING THE GENERATOR 8 Woodruff key 1 9 Starter clutch gear 1 Refer to REMOVING INSTALLING THE STARTER CLUTCH 10 Starter clutch 1 F...

Page 344: ...b Part Q ty Remarks Removing the stator assembly Remove the parts in the order listed 1 Lead holder 1 Refer to INSTALLING THE GENERA TOR 2 Stator assembly 1 For installation reverse the removal proced...

Page 345: ...r all of the bolts are fully loosened remove them 2 Remove generator rotor bolt 1 washer NOTE While holding the generator rotor 2 with the primary sheave holder 3 loosen the genera tor rotor bolt Prim...

Page 346: ...HE STARTER CLUTCH 1 Check starter clutch rollers 1 Damage wear Replace 2 Check starter clutch idle gear 1 starter clutch gear 2 Burrs chips roughness wear Replace the defective part s 3 Check starter...

Page 347: ...freely otherwise the starter clutch is faulty and must be replaced EAS00355 INSTALLING THE STARTER CLUTCH 1 Install starter clutch starter clutch bolts 1 NOTE While holding the generator rotor with t...

Page 348: ...he generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the generator rotor bolt and washer with engine oil 4...

Page 349: ...pter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3...

Page 350: ...nkshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 Refer to INSTALLING THE PICKUP COIL ROTOR 6 Pickup coil rotor 1 Refer to REMOVING INSTALLING THE PICKUP COIL ROTOR For insta...

Page 351: ...hem 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the primary sheave holder 4 remove the pickup coil rotor bolt Primary sheave holder YS 01...

Page 352: ...pickup coil rotor bolt Primary sheave holder YS 01880 A T R 45 Nm 4 5 m kg 32 ft lb 3 Apply sealant onto the crankshaft position sensor lead grommet Quick Gasket ACC 11001 05 01 4 Install pickup coil...

Page 353: ...ty Remarks Removing the clutch cover Remove the parts in the order listed Right side cowling Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1...

Page 354: ...IC CLUTCH in chap ter 4 Rear balancer Refer to BALANCERS 1 Oil guide plate 1 Refer to REMOVING INSTALLING THE CLUTCH 2 Clutch spring plate retainer 1 3 Clutch spring plate 1 4 Clutch spring plate seat...

Page 355: ...OVING INSTALLING THE CLUTCH 13 Clutch boss 1 14 Wire circlip 1 15 Clutch plate 2 1 16 Friction plate 3 1 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Thrust washer 1 20 Spacer 1 21 Clut...

Page 356: ...aighten the lock washer tab 4 Loosen clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder YM 91042 5 Remove clu...

Page 357: ...tallation Insert two 5 mm 0 20 in bolts 2 into the spacer and then remove the spacer by pull ing on the bolts EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fricti...

Page 358: ...a set Maximum Maximum clutch plate warpage 0 1 mm 0 004 in EAS00283 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate 1 Damage Replace 2 Check clutch spring plate seat 2 Damage Replace EAS0...

Page 359: ...KING THE CLUTCH PUSH RODS 1 Check O ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks damage wear Replace the defec tive part s 2 Measure long clutch push rod bending Out of specific...

Page 360: ...of the holes of the clutch housing and primary driven gear and then rotate the inner pri mary driven gear until both primary driver gears are aligned The teeth of both primary driven gears must be al...

Page 361: ...de of the nut Universal clutch holder YM 91042 New T R 90 Nm 9 0 m kg 65 ft lb 6 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Recommended lubricant Li...

Page 362: ...plate seat 2 clutch spring plate 3 clutch spring plate retainer 4 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 11 Install rear balancer weight Refer to BALANCERS T R 8 Nm...

Page 363: ...ft shaft Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Clutch housing Refer to CLUTCH 1 Oil baffle plate 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft...

Page 364: ...Job Part Q ty Remarks 6 Stopper lever spring 1 Refer to INSTALLING THE SHIFT SHAFT 7 Stopper lever 1 8 Circlip 1 9 Collar 1 10 Shift shaft spring stopper 1 For installation reverse the removal procedu...

Page 365: ...per lever stopper lever spring 2 Damage wear Replace EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stoppe...

Page 366: ...5 57 ENG 3 Install shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm T R 10 Nm 1 0 m kg 7 2 ft lb SHIFT SHAFT...

Page 367: ...bly Refer to ENGINE Air filter case Refer to AIR FILTER CASE in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Sidestand 1 2 Oil level switch connector 1 Disconnect 3 Oil l...

Page 368: ...Q ty Remarks 9 Oil strainer 1 Refer to INSTALLING THE OIL STRAINER 10 Dowel pin 2 11 Oil pump 1 Refer to INSTALLING THE OIL PUMP 12 Relief valve assembly 1 For installation reverse the removal procedu...

Page 369: ...ing the oil pump Remove the parts in the order listed 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump shaft 1 8 Oil pump housing 1 Fo...

Page 370: ...Check oil pump shaft 1 oil pump housing 2 oil pump housing cover 3 Cracks damage wear Replace the defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing...

Page 371: ...IL 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 EAS00368 CHEC...

Page 372: ...il pump turns smoothly T R 12 Nm 1 2 m kg 8 7 ft lb LT EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer cover must point towards the front of the engi...

Page 373: ...5 64 ENG WARNING Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil OIL PAN AND OIL PUMP...

Page 374: ...N AND OIL PUMP 1 Left middle gear cover 1 2 Left middle gear cover gasket 1 3 Dowel pin 2 4 Right middle gear cover 1 5 Bearing 1 6 Middle driven shaft end cover 1 7 Oil seal 1 8 Middle driven pinion...

Page 375: ...ASSEMBLY 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 Refer to REMOVING THE MIDDLE GEAR and INSTALLING THE...

Page 376: ...Remove the parts in the order listed 1 Spring retainer 2 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVE SHAFT ASSEMBLY 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1...

Page 377: ...the order listed 1 Middle driven pinion gear nut 1 2 Middle driven shaft 1 3 Middle driven pinion gear 1 4 Bearing retainer 1 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 Bear...

Page 378: ...e holding the middle drive shaft 2 3 Straighten the lock washer tab 4 Loosen middle drive shaft nut 1 NOTE While holding the middle drive shaft 2 5 Straighten the punched point of the middle drive sha...

Page 379: ...ing compressor push plate YM 33286 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Straighten the punched point of the bearing retainer 2 Loosen bearing retainer 1 with the bearing retainer wrench 2...

Page 380: ...seal Damage Replace the defective part s EAS00440 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install spring retainers 1 NOTE While compressing the spring with the spring compressor push plate 2 ins...

Page 381: ...VE SHAFT ASSEMBLY 1 Install middle drive shaft shim bearing bearing retainer 1 with the middle drive shaft retainer wrench 2 NOTE Lock the threads on the bearing retainer by staking them with a center...

Page 382: ...iddle driven shaft assembly 1 middle driven shaft shims 2 middle driven shaft bearing housing bolts NOTE Finger tighten the middle driven shaft housing bolts 2 Tighten middle driven shaft nut 1 NOTE W...

Page 383: ...lb EAS00449 MEASURING THE MIDDLE GEAR BACKLASH 1 Measure middle gear backlash Out of specification Refer to ADJUST ING THE MIDDLE GEAR BACKLASH a Install the gear lash measurement tool 1 as shown b Ma...

Page 384: ...ACKLASH 1 Loosen middle driven shaft bearing housing bolts 2 Remove shim s 3 Tighten middle driven shaft bearing housing bolts CAUTION Do not overtighten the middle driven shaft bearing housing bolts...

Page 385: ...ng housing should be approximately 2 mm 0 08 in when mea sured with a thickness gauge 1 4 Hold the middle drive shaft 1 5 Turn middle driven shaft NOTE While carefully tightening the middle driven sha...

Page 386: ...ere fore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm 0 016 in shim Shims are supplied in the following thick nesses Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9...

Page 387: ...at has had its respective thickness calculated from infor mation marked on the crankcase and the end of the middle drive gear 1 Middle drive gear shim thickness A 2 Middle drive gear shim thickness B...

Page 388: ...gear which is added to the nominal size 34 e Measured value f a numeral on the upper crankcase near the main bearing selection numbers and which is added to the nominal size 88 Example If the middle d...

Page 389: ...5 80 ENG Shims are supplied in the following thick nesses Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive shaft shim Thickness mm 0 10 0 15 0 30 0 40 0 50 0 60 MIDDLE GEAR...

Page 390: ...listed Engine Refer to ENGINE Cylinder head Refer to CYLINDER HEAD Generator rotor Refer to GENERATOR AND STARTER CLUTCH Pickup coil rotor Refer to PICKUP COIL ROTOR Stopper lever Refer to SHIFT SHAF...

Page 391: ...2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Collar 1 6 Spacer 1 7 Neutral switch 1 8 Speed sensor 1 9 Lower crankcase 1 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE 10 Dowel...

Page 392: ...t Q ty Remarks Removing the oil baffle plates and bearings Remove the parts in the order listed Connecting rod assemblies Refer to CONNECTING RODS AND PISTONS Crankshaft crankshaft journal bearings Re...

Page 393: ...0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 12 Nm 1 2 m kg 8 7 ft Ib Order Job Part Q ty Remarks 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter bolt 1 11 Lower crankcase...

Page 394: ...crankcase indicate the crankcase tightening sequence 2 Place the engine upside down 3 Remove lower crankcase CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por...

Page 395: ...nd crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean...

Page 396: ...camshaft sprockets as a set oil pump drive chain 2 Damage stiffness Replace the oil pump drive chain oil pump drive sprocket and oil pump shaft as a set 2 Check oil pump drive sprocket Cracks damage...

Page 397: ...n 2 3 mm 0 08 0 12 in of the crankshaft journal bear ings 3 Install dowel pins Quick Gasket ACC 11001 05 01 4 Set the shift drum assembly and transmis sion gears in the neutral position 5 Install lowe...

Page 398: ...mm bolts U New 7 Tighten crankcase bolts 1 0 NOTE Do not reuse crankcase bolts 1 0 The tightening procedure of crankcase bolts 1 0 is angle controlled therefore tighten the bolts using the following...

Page 399: ...ure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagonal bolt note that the angle from on...

Page 400: ...r listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 Refer to REMOVING THE CONNECT ING RODS AND PISTONS and INSTALLING THE CONNECTING RODS AND PISTONS 2 Big end lower bearing 4 3 Pist...

Page 401: ...ace 2 Remove piston pin clips 1 piston pin 2 piston 3 connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the p...

Page 402: ...ngs as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cyl...

Page 403: ...iston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 020 0 045 mm 0 0008 0 0018 in Limit 0 012 mm 0 0005 in EAS00263 CHECKING THE PISTON RINGS 1 Measure p...

Page 404: ...the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 35 0 45 mm 0 014 0 018 in Limit 0 70 mm 0 028 in 2nd ring 0 75 0 85 mm 0 030 0 033 in Limit 1 20 mm...

Page 405: ...cification Replace the piston Piston pin bore diameter in the piston 19 004 19 015 mm 0 7482 0 7486 in Limit 19 045 mm 0 7498 in 4 Calculate piston pin to piston clearance Out of specification Replace...

Page 406: ...aring into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting r...

Page 407: ...rings 2 Select big end bearings P1 P4 NOTE The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to...

Page 408: ...Install piston 1 connecting rod 2 piston pin 3 piston pin clip 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod left when the arrow mark b on the piston i...

Page 409: ...ricant Recommended lubricant Engine oil 7 Install big end bearings connecting rod assembly 1 into the cylinder and onto the crankshaft pin connecting rod cap onto the crankshaft pin NOTE Align the pro...

Page 410: ...WARNING Replace the connecting rod bolts and nuts with new ones Clean the connecting rod bolts and nuts NOTE The tightening procedure of the connecting rod nuts is angle controlled therefore tighten...

Page 411: ...hten it Replace the nut with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified angle Tighten the nut until it is at the specified angle...

Page 412: ...ts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 Refer to REMOVING INSTALLING THE CRANKSHAFT 2 Crankshaft journal lo...

Page 413: ...EAS00396 CHECKING THE CRANKSHAFT 1 Measure crankshaft runout Out of specification Replace the crank shaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check crankshaft journal surfaces crankshaft pin...

Page 414: ...crankshaft jour nal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 2 on each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the cranksh...

Page 415: ...rs stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use th...

Page 416: ...gs into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in its or...

Page 417: ...ift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Drive axle assembly 1 Refer to INSTALLING THE TRANSMIS SION 2 Bearing 1 3 Washer 1 4 Shift drum retainer 1 5 Long...

Page 418: ...Q ty Remarks 10 Shift drum assembly 1 Refer to INSTALLING THE TRANSMIS SION 11 Shift fork C 1 12 Main axle assembly 1 Refer to REMOVING INSTALLING THE TRANSMISSION For installation reverse the remova...

Page 419: ...e main axle assem bly Remove the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circ...

Page 420: ...5 111 ENG New M M M M New Order Job Part Q ty Remarks A Main axle 1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For assembly reverse the disassembly procedure TRANSMISSION...

Page 421: ...rks Disassembling the drive axle assembly Remove the parts in the order listed 1 Middle drive gear 1 2 Bearing 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 washer 1 7 5th wheel gear 1 8 Circlip 2 9 To...

Page 422: ...Q ty Remarks A Toothed spacer 1 B Toothed lock washer 1 C Toothed lock washer retainer 1 D 4th wheel gear 1 E Washer 1 F 1st wheel gear 1 G Bearing 1 H Washer 1 I Drive axle 1 For assembly reverse th...

Page 423: ...clutch side NOTE Remove the main axle assembly with the slide hammer bolt 1 and weight Slide hammer bolt YU 01083 1 Weight J 6125 7 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies t...

Page 424: ...rk guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum assembly shift drum segment 1 Damage wear Replace the shift drum...

Page 425: ...ation pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective...

Page 426: ...sponding hole in the upper crankcase The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Make sure the drive axle bearing circ...

Page 427: ...cer Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Balancer lever 1 Refer to INSTALLING THE FRONT BALANCER 2 Balancer shaft 1 3 Washer 2 4 Bearing 2 5 Balancer gear 1 6 A...

Page 428: ...es Refer to FUEL INJECTION SYSTEM in chapter 7 Clutch cover Refer to CLUTCH 1 Balancer cover 1 2 Balancer cover gasket 1 3 Balancer lever 1 Refer to INSTALLING THE REAR BAL ANCER 4 Balancer shaft 1 5...

Page 429: ...n bearings 2 Damage wear Replace absorbers Damage wear Replace INSTALLING THE FRONT BALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the b...

Page 430: ...stalling the balancer shaft 4 Install balancer lever 1 balancer lever bolt 2 NOTE Temporarily tighten the balancer lever bolt LT 5 Tighten balancer shaft 1 NOTE Tighten the balancer shaft to the speci...

Page 431: ...ALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the balancer weight with the mark b in the balancer gear 2 Align T mark on the pickup coil...

Page 432: ...ven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the primary driven gear point d Make sure that the slot e is facing in the direction indicated in the illus...

Page 433: ...olt 1 balancer shaft pinch bolt 2 NOTE Make sure that the balancer shaft does not rotate T R 14 Nm 1 4 m kg 10 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 7 Start the engine and check that there is no abnormal...

Page 434: ...r to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator cap 1 2 Coolant...

Page 435: ...1 Conduit hose 1 12 Radiator inlet hose 1 Disconnect 13 Plunger control unit hose 2 1 Disconnect 14 Oil cooler outlet hose 1 Disconnect 15 Horn connector 4 Disconnect 16 Radiator fan motor coupler 1 D...

Page 436: ...sure Below the specified pressure Replace the radiator cap a Install the radiator pressure tester 1 and radiator pressure tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten...

Page 437: ...he specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below...

Page 438: ...d Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Radiator assembly Refer to RADIATOR 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jac...

Page 439: ...faces of the oil cooler and the crankcase with a cloth dampened with lacquer thin ner 2 Install O ring oil cooler NOTE Make sure the O ring is positioned properly 3 Fill cooling system with the specif...

Page 440: ...COOL OIL COOLER 4 Check cooling system Leaks Repair or replace any faulty part 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIA...

Page 441: ...chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Air cut off valve assembly hoses Refer to AIR INDUCTION SYSTEM in chapter 7 1 Plunger control unit hose 1 1 Disconnect 2 Thermostat a...

Page 442: ...ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed 1 Thermostat housing cover 1 Refer to ASSEMBLING THE THERMO STAT ASSEMBLY 2 Thermostat 1 3 Thermostat housing 1 F...

Page 443: ...e water observe the ther mostat and thermometer s indicated tem perature 1 Thermostat 2 Thermometer 3 Water 4 Container Fully closed Fully open NOTE If the accuracy of the thermostat is in doubt repla...

Page 444: ...ERMOSTAT ASSEMBLY 1 Lubricate O ring thermostat assembly and thermo stat assembly inlet pipe 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT i...

Page 445: ...der listed NOTE It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Right side cowling Refer to COWLINGS AND COVERS in chapter 3 E...

Page 446: ...Part Q ty Remarks 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump 1 Refer to INSTALLING THE WATER PUMP For installation...

Page 447: ...the parts in the order listed 1 Water pump housing cover 1 Refer to ASSEMBLING THE WATER PUMP 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8...

Page 448: ...from the inside of the water pump housing 2 3 Remove oil seal 1 bearing 2 NOTE Tap out the bearing and oil seal from the out side of the water pump housing EAS00473 CHECKING THE WATER PUMP 1 Check wa...

Page 449: ...CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools Before installing the water pump seal apply Quick Gasket 2 to the water...

Page 450: ...Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in 5 Install impeller 1 circlip NOTE After installation check that the impeller shaft rotates smoothly New 6 Install O ring NOTE Lubricat...

Page 451: ...New T R 12 Nm 1 2 m kg 8 7 ft lb 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount of the recom...

Page 452: ...hose 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A O2 sensor B Catalytic converter C Crankshaft position sensor D Coolant temperature sensor E Spark plug F Cylinder identi...

Page 453: ...Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L...

Page 454: ...fuel injection stop function is active the warning light blinks while the start switch is being pressed to start the engine If a malfunction in the system is detected by the self diagnostic function...

Page 455: ...ight illuminates 1 4 seconds each time the main switch is turned ON The ECU performs a self diagnosis during this time and turns OFF the light thereafter 2 Warning control when unable to start engine...

Page 456: ...y observing the self diagnostic fault code number that appears on the multi function meter and cross referencing it on the fault code number table When used in conjunction with the troubleshooting det...

Page 457: ...el ratio feed back compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Able Able 14 Faulty intake air pressure sensor pipe system a hose is detached causing...

Page 458: ...isted up to that point Able Able 12 Crankshaft position sen sor Stops the engine by stopping the injection and ignition Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system...

Page 459: ...lect the applicable sensor or actuator from the diagnostic code table If a diagnostic code is available proceed with the operation procedure given below in order to verify the operating conditions of...

Page 460: ...g the operation of the displayed diagnostic code Verifying various sensors The data representing the operating con ditions of the sensors appears on the trip LCD throttle position sensor angle cool an...

Page 461: ...einstating the ECU Verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera tion that is applicable to the malfunctioning item Refer to...

Page 462: ...e air pressure sensor Malfunction in ECU 03 Or a stuck throttle position sensor is detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective sensor stuck thro...

Page 463: ...in ECU Malfunction in other areas of the fuel system 33 Open circuit is detected in the primary wire of the ignition coil 1 4 Open or short circuit in wiring harness Malfunction in ignition coil Malfu...

Page 464: ...n of the vehicle pulses that are gen erated when the tire is spun 0 999 resets to 0 after 999 OK if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off switch...

Page 465: ...or 4 Take the same actions as No 36 on injector 4 If the engine stop switch is ON turn it OFF once and then turn it back ON Same as above 48 AI system solenoid After 1 second has elapsed from the time...

Page 466: ...shooting through the self diagnostic function Refer to Troubleshooting details Light does not turn ON NG Inspect and repair the wiring harness OK Only the engine trouble warning light does not turn O...

Page 467: ...ing condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Code No 12 Symp...

Page 468: ...instated by turn ing the main switch ON Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White...

Page 469: ...te Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue Defective intake air pressure sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 3 Open or short circui...

Page 470: ...0 V Power supply wire open circuit 0 V Check for open circuit and replace the throttle position sensor Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or shor...

Page 471: ...Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black...

Page 472: ...e main switch ON Defective coolant temperature sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Open or short circuit in wiring harness or sub lead Repair or replace if there is...

Page 473: ...ure sensor coupler Main wiring harness ECU coupler Code No 24 Symptom No normal signal is received from the O2 sensor Used diagnostic code No Inspection operation item and probable cause Operation ite...

Page 474: ...f defective Reinstated by starting the engine warming it up until the coolant tem perature is 60 C 140 F or more and then running it between 2 000 3 000 r min until the engine trouble indicator turns...

Page 475: ...or short circuit Main wiring harness Black Blue White Gray Green Blue The fuel pressure is too high Compare the fuel pressure at idle and with throttle open About the same Normal Too high Inspect the...

Page 476: ...nd secondary coils for continuity Replace if defective Refer to IGNITION SYSTEM in chapter 8 Reinstated by starting the engine and operating it at idle Open or short circuit in lead wire Repair or rep...

Page 477: ...Replace if defective Refer to TRANSMISSION in chapter 5 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Main wiring harness Sky blue Sky blue 2 Connected s...

Page 478: ...nction is detected in the ECU the fault code number might not appear on the meter Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement m...

Page 479: ...gnosis mode Using the results of the diagnosis mode inspection as reference estimate the cause of the mal function and carry out the inspection and repair of the affected area Symptom The engine troub...

Page 480: ...e headlight relay 1 Check the operation of the headlight Classify the malfunctions Malfunction related to the relay Malfunction related to the wiring harness Malfunction in the headlight itself Relay...

Page 481: ...fan does not operate Inspect the fan Refer to COOLING SYSTEM in chapter 8 Defective replace Check the continuity at the contact point of the radiator fan motor relay Refer to COOLING SYSTEM in chapte...

Page 482: ...od 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode and in case the area of the malfunction has been narrowed down in the...

Page 483: ...em relay Open circuit in wiring harness Disconnected battery Defective crankshaft position sensor Defective sidestand switch Tripped lean angle cut off switch Open circuit in ignition coil primary lin...

Page 484: ...ber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 O2 sensor coupler 1 Disconnect 2 Cy...

Page 485: ...5 5 11 11 3 8 8 7 11 11 6 Order Job Part Q ty Remarks 8 Throttle cable 2 Disconnect 9 Plunger control unit hose 1 1 Disconnect 10 Plunger control unit hose 2 1 Disconnect 11 Throttle body joint 4 For...

Page 486: ...sconnect 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor 1 Disconnect 4 Cylinder 1 injector coupler 1 Disconnect 5 Cylinder 2 injector coupler 1 Disconnect 6 Cylinder 3 in...

Page 487: ...ION SYSTEM 10 12 4 5 6 7 2 8 3 9 11 13 14 15 1 Order Job Part Q ty Remarks 12 Intake air pressure sensor 1 13 Fuel distributor 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse th...

Page 488: ...DY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor clean...

Page 489: ...lator at the joint c Connect the mity vac set 2 onto the nega tive pressure hose from the pressure regu lator d Connect the pressure gauge 3 and adapter 4 onto the fuel injector pipe e Install the fue...

Page 490: ...vacuum pressure as described below NOTE The vacuum pressure should not exceed 100 kPa 1 mm Hg 0 039 in Hg Faulty Replace the pressure regulator Increase the vacuum pressure Fuel pressure is decreased...

Page 491: ...ed exhaust gases is approximately 600 1 112 F to 700 C 1 292 F EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions...

Page 492: ...7 41 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut off valve 2 Reed valve 3 Air filter case To cylinder 4 To cylinder 3 To cylinder 2 To cylinder 1 1 2 4 3...

Page 493: ...ng the air cut off valve assembly and hoses Remove the parts in the order listed Rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 1 Air cut off valve assembly 1 2 Hose...

Page 494: ...s Remove the parts in the order listed Air cut off valve assembly hoses Thermostat assembly Refer to THERMOSTAT in chapter 6 Spark plug caps 1 Reed valve cover 1 1 2 Reed valve cover 2 3 1 3 Reed valv...

Page 495: ...CTION SYSTEM 1 Check hoses Loose connection Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed fibre reed stopper reed valve seat Cracks damage Replace the reed valv...

Page 496: ...ts fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 1 Clamp 2 2 Canister charge hose 1 Disconnect 3 Rollover valve 1 4 Canis...

Page 497: ...ield drive unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake switch 6 Clutch switch 7 Fuse box 8 Radiator fan motor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil lev...

Page 498: ...e sensor 4 Atmospheric pressure sensor 5 Lean angle cut off switch 6 ECU 7 Starting circuit cut off relay 8 Speed sensor 9 Cylinder identification sensor 0 O2 sensor A Crankshaft position sensor B Hea...

Page 499: ...When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration simila...

Page 500: ...TINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch R W L W B R B R W B W B R B R W Y Br L W BLACK L Y B Y B Y L Y BLACK BLACK B...

Page 501: ...4 Dimmer switch 5 Horn switch 6 Windshield position switch 7 Turn signal switch 8 Front brake light switch 9 Engine stop switch 0 Start switch A Rear brake light switch B Neutral switch C Sidestand s...

Page 502: ...B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning...

Page 503: ...f 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 2 Check bulb for continuity wit...

Page 504: ...ter No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect...

Page 505: ...W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B...

Page 506: ...spark Dynamic spark tester YM 34487 Pocket tester YU 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignitio...

Page 507: ...ignition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark plug lead Connect the pocket tester 1k to the...

Page 508: ...n Tester positive probe gray 1 Tester negative probe black 2 Measure the crankshaft position sensor resistance Crankshaft position sensor resis tance 420 8 569 3 at 20 C 68 F between gray and black Is...

Page 509: ...cut off relay for continuity Tester positive probe blue green 1 Tester negative probe blue yellow 2 Continu ity Tester positive probe blue yellow 1 Tester negative probe blue green 2 No conti nuity Lg...

Page 510: ...D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W...

Page 511: ...the starter motor from operating when neither of these conditions 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 o...

Page 512: ...03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the con...

Page 513: ...y from the wire harness Connect the pocket tester 1 to the starting circuit cut off relay terminals as shown Measure the starting circuit cut off relay for continuity as follows Lg L G L Y Sb B Y B R...

Page 514: ...Tester positive probe red 3 Tester negative probe black 4 Does the starter relay have continuity between red and black Replace the starter relay R B R L W R W 7 Main switch Check the main switch for c...

Page 515: ...K Replace the clutch switch 12 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch 13 Wiring Check the entire st...

Page 516: ...der Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Throttle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 1 Starter motor lead 1 Disconnect 2 Starter motor...

Page 517: ...ft Ib Order Job Part Q ty Remarks Disassembly the starter motor Remove the parts in the order listed 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat 1 5 Washer 1 6 Lock washer 1 7 Oil...

Page 518: ...w New New 1 2 6 5 4 3 3 7 8 C A B A 0 9 T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks A O ring 1 B Starter motor yoke 1 C Armature assembly 1 For assembly reverse the disassembly procedure S...

Page 519: ...pecification Replace the starter motor Commutator wear limit 23 5 mm 0 93 in 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been...

Page 520: ...YU 03112 Armature coil Commutator resistance 1 0 024 0 030 at 20 C 68 F Insulation resistance 2 Above 1 M at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush...

Page 521: ...he brush seat with the tab b in the starter motor front cover 2 Install starter motor yoke 1 starter motor front cover 2 starter motor rear cover 3 NOTE Align the match marks a on the starter motor yo...

Page 522: ...Sb B Y L W B R B Lg R B L G L Y B Y L Y z Br L Br L L Br G Br L R W R W R W Br L R W L W R B Br L Br Br B Br B Br B B R B R B C R R B L Y L Y B R L R L R B R L Y R L A A Br G Br G A Br W Br W A G B G...

Page 523: ...or continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum...

Page 524: ...ter positive probe white 1 Tester negative probe white 2 Tester positive probe white 1 Tester negative probe white 3 Measure the stator coil resistances Stator coil resistance 0 15 0 23 at 20 C 68 F I...

Page 525: ...L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E...

Page 526: ...ight high beam indicator light taillight or meter light Pocket tester YU 03112 1 Main tail position light and headlight fuses Check the main tail position light and head light fuses for continuity Ref...

Page 527: ...e headlight relay 1 for continuity Battery positive terminal blue black 1 Battery negative terminal yellow black 2 Tester positive probe red yellow 3 Tester negative probe green blue 4 Does the headli...

Page 528: ...s the lighting system s wiring properly con nected and without defects Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair t...

Page 529: ...st be repaired R W G W Y L Lg Y Ch Dg L R G B W Br R W 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Are the meter light bulb and socket OK Replace the meter light...

Page 530: ...age Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Tester positive probe blue 1 Tester negative probe black 2 Set the main switch to ON Measure the voltag...

Page 531: ...8 35 ELEC LIGHTING SYSTEM...

Page 532: ...Y L Y R L B L Y G Y B k c Ch B Y G B B G P G B Y G B Y L R G W R L O B O B O B B L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B...

Page 533: ...ing light _ Left turn signal indicator light a Right turn signal indicator light c Oil level switch h Turn signal switch i Horn switch j Horn k Front turn signal light left l Front turn signal light r...

Page 534: ...lighting windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system hazard lighting windshield motor and backup fuses OK Replace the fuse s...

Page 535: ...the horn terminal as shown Tester positive probe brown 1 Tester negative probe ground Set the main switch to ON Measure the voltage 12 V of black white at the horn terminal Is the voltage within spec...

Page 536: ...the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail light assembly coupler wire harness side as shown Tester positive probe yellow 1 Teste...

Page 537: ...Is the turn signal switch OK Replace the left han dlebar switch 3 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Tester positive probe brown green 1 Tester negati...

Page 538: ...signal light Tester positive probe dark green 2 Tester negative probe ground Ch Dg Ch Dg Ch B Y L Dg Y L B 1 2 R W G W Y L Lg Y Ch Dg L R G B W Br R W Set the main switch to ON Set the turn signal sw...

Page 539: ...onti nuity NOTE When you switch the positive and negative tester probes the readings in the above chart will be reversed Are the tester readings correct Replace the starting circuit cut off relay Lg L...

Page 540: ...pan Check the engine oil level switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine oil level switch OK Replace the engine oil level switch 3 Voltage Connect the pocket tester DC 20 V t...

Page 541: ...e stopper Fuel sender resistance Full position of the float 19 21 at 20 C 68 F Empty position of the float 139 141 at 20 C 68 F Is the fuel sender OK Replace the fuel pump G W B B R L 2 Voltage Connec...

Page 542: ...L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y...

Page 543: ...e coolant temperature gauge needle fails to move when the engine is warm Pocket tester YU 03112 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for co...

Page 544: ...ect the green white 1 and black blue 2 terminals with a jumper lead 3 shown Does the radiator fan motor turn The radiator fan motor is faulty and must be replaced G W B L 6 Radiator fan motor relay Di...

Page 545: ...t step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating pha...

Page 546: ...iring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly con nected and without defects Replace the ECU Properly connect or repair the cooling sy...

Page 547: ...Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L...

Page 548: ...EAS00749 YES NO EAS00750 YES NO If the fuel injection system fails to oper ate Pocket tester YU 03112 1 Main fuel injection system and ignition fuses Check the main fuel injection system and ignition...

Page 549: ...k Replace the fuel injection system relay R R L R B L Y 6 Fuel pump resistance Disconnect the fuel pump coupler from the fuel pump Connect the pocket tester 1 to the fuel pump coupler as shown Tester...

Page 550: ...ification sensor output voltage Cylinder identification sensor output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less Is the cylinder identification sensor OK Replace th...

Page 551: ...Test step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating...

Page 552: ...bject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it T R Intake air temperature sensor 18 Nm 1 8 m kg 13 ft lb Is the intake air temperat...

Page 553: ...atmo spheric pressure sensor L B L P 14 AI system solenoid Remove the AI system solenoid coupler from the wire harness Connect the pocket tester 1 to the AI system solenoid terminal as shown Tester p...

Page 554: ...oline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check...

Page 555: ...osition sensor d Connect the pocket tester 1k to the throttle position sensor e While slowly opening the throttle check that the throttle position sensor resistance is within the specified range NOTE...

Page 556: ...e throttle position sensor b Remove the throttle position sensor from the throttle body c Connect the pocket tester 1k to the throttle position sensor d Measure the maximum throttle position sen sor r...

Page 557: ...ightly from those specified Tester positive probe yellow terminal 3 Tester negative probe black blue terminal 2 Throttle position sensor resis tance 0 5 1 0 k at 20 C 68 F yellow black blue 3 Adjust t...

Page 558: ...lds Loosen the throttle posi tion sensor screws 4 Connect the pocket tester 100 to the throttle position sensor e Adjust the throttle position sensor angle so the measured resistance is within the spe...

Page 559: ...B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y...

Page 560: ...the main windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main windshield motor and backup fuses OK Replace the fuse s 2 Battery Check the condition o...

Page 561: ...ink until the windshield has stopped and is all the way down If the neutral indicator light does not turn off replace the windshield drive unit 5 Wiring Check the entire windshield drive system s wiri...

Page 562: ...r damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly...

Page 563: ...Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incor...

Page 564: ...FT 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 Transmiss...

Page 565: ...ed clutch release cylinder Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00855 OVERHEATING ENGINE Clogged coolant passages Heavy carbon buildu...

Page 566: ...EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod...

Page 567: ...EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts...

Page 568: ...INKS QUICKLY Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb HORN DOES NOT SOUND Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Fa...

Page 569: ...l level warning light Z Neutral indicator light Multi function meter Engine trouble warning light High beam indicator light _ Left turn signal indicator light a Right turn signal indicator light b Met...

Page 570: ......

Page 571: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A...

Page 572: ...e White Yellow White Black Yellow Black Yellow Green Yellow Blue Yellow Red D D D R LR B D ON OFF 1 RED RED BLACK BLACK BLACK BLACK BLACK GRAY 9 F 0 7 8 6 A A A A B C B B A A A A A A B B B B y BLACK B...

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