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Yamaha FZ09E 2014 Service Manual Download Page 4

EAS20071

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information 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.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

TIP

•

This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.

•

Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol 

to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could 

result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid 

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

Summary of Contents for FZ09E 2014

Page 1: ...2014 SERVICE MANUAL FZ09E FZ09EC LIT 11616 27 39 1RC 28197 10 ...

Page 2: ......

Page 3: ... by Yamaha Motor Corporation U S A First edition August 2013 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 27 39 ...

Page 4: ...mer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual co...

Page 5: ...e section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing th...

Page 6: ...rviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one Silicone fluid G M BF B T R LS M S LT E New S ...

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

Page 8: ......

Page 9: ...NCTIONS 1 4 YCC T Yamaha Chip Controlled Throttle 1 9 IMPORTANT INFORMATION 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS 1 11 GASKETS OIL SEALS AND O RINGS 1 11 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND OIL SEALS 1 11 CIRCLIPS 1 12 RUBBER PARTS 1 12 BASIC SERVICE INFORMATION 1 13 QUICK FASTENERS 1 13 ELECTRICAL SYSTEM 1 13 SPECIAL TOOLS 1 18 ...

Page 10: ...20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 ...

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

Page 12: ...nput from the throttle position sensor accelerator position sensor coolant temperature sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that...

Page 13: ...between kilometers and miles press the SELECT button for at least one second Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer will sweep across the r min range and then re turn to zero r min in order to test the electrical cir cuit NOTICE ECA10032 Do not operate the engine in the tachometer r...

Page 14: ...el segments and fuel level warning indicator flash eight times then go off for approximately 3 seconds Refer to CHECKING THE FUEL METER FU EL LEVEL WARNING LIGHT on page 8 105 Eco indicator This indicator comes on when the vehicle is be ing operated in an environmentally friendly fu el efficient manner The indicator goes off when the vehicle is stopped TIP Consider the following tips to reduce fue...

Page 15: ...ting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter odometer in stantaneous fuel consumption and average fuel consumption modes in the following order F TRIP km L L 100 km or MPG AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG F Air_ _ F ODO TRIP 1 TRIP 2 F TRIP To reset a tripmeter select it by pushing the SE LECT butt...

Page 16: ... in 1 F increments If the message HI flashes stop the vehicle then stop the engine and let the engine cool TIP When the coolant temperature is below 104 F LO will be displayed The coolant temperature varies with changes in the weather and engine load Air intake temperature display The air intake temperature display indicates the temperature of the air drawn into the air filter case This display sh...

Page 17: ...iginal display D mode drive mode D mode is an electronically controlled engine performance system with three mode selections STD A and B Push the drive mode switch MODE to switch between modes TIP Before using D mode make sure you under stand its operation along with the operation of the drive mode switch Mode STD Mode STD is suitable for various riding condi tions This mode allows the rider to en...

Page 18: ...respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability ...

Page 19: ... 5 6 7 8 9 3 2 1 4 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU engine control unit 5 Sensor input 6 Gear position sensor 7 Crankshaft position sensor 8 Speed sensor 9 Coolant temperature sensor ...

Page 20: ...ep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil se...

Page 21: ...ng surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS32080 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are s...

Page 22: ...sh the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastener insert the fastener into the part to be secured and tighten the screw a EAS30401 ELECTRICAL SYSTEM Electrical parts ha...

Page 23: ...s could damage the electrical components NOTICE ECA16770 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead If a tool or similar item contacts the vehicle while only the negative battery lead is con nected a spark could be generated which is extremely dangerous NOTICE ECA16610 Turn the main switch to OFF before dis co...

Page 24: ... loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert the tester probes directly into the coupler When performing any checks using a waterproof coupler use the specified test harness or a suitable commercially available test har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE EC...

Page 25: ...al times 3 Connect Lead Coupler Connector TIP When connecting a coupler or connector push both sections of the coupler or connector to gether until they are connected securely Make sure all connections are tight 4 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer ...

Page 26: ...ed at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 k at 0 C 32 F 290 390 at 80 C 176 F ...

Page 27: ...n placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 61 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 61 Radiator cap tester 90890 01325 Mityvac c...

Page 28: ... 4 61 Damper rod holder 90890 01423 Damping rod holder YM 01423 4 52 4 53 Oil filter wrench 90890 01426 YU 38411 3 23 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 51 4 56 4 57 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 55 4 56 4 57 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 29: ... driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 54 4 55 Pivot shaft wrench adapter 90890 01476 5 7 5 8 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 7 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 5 7 5 8 Drive chain cut rivet tool 90890 01550 YM 01550 4 71 4 73 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 30: ...90 03094 Vacuummate YU 44456 3 8 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 16 1 17 8 91 8 92 8 93 8 97 8 98 8 99 8 100 8 101 8 103 8 104 8 105 8 106 8 107 8 108 8 110 8 111 Oil pressure adapter H 90890 03139 3 24 Pressure gauge 90890 03153 YU 03153 3 24 7 11 Carburetor angle driver 2 90890 03173 3 9 Tool name Tool No Illustration Reference pages YU 44456 ...

Page 31: ...0 5 43 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 105 8 109 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 101 Fuel injector pressure adapter 90890 03210 YU 03210 7 11 Yamaha diagnostic tool 90890 03215 8 37 Valve spring compressor 90890 04019 YM 04019 5 23 5 28 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 11 Tool name To...

Page 32: ...YM A8998 3 6 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 23 5 28 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 25 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 25 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 25 Tool name Tool No Illustration Reference pages ...

Page 33: ...ng tool 90890 04161 YM 04161 5 68 Camshaft wrench 90890 04162 YM 04162 5 12 5 14 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 100 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 34 5 57 Tool name Tool No Illustration Reference pages ...

Page 34: ...SPECIAL TOOLS 1 25 ...

Page 35: ...HTENING TORQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 41 ...

Page 36: ...gth 2075 mm 81 7 in Overall width 815 mm 32 1 in Overall height 1135 mm 44 7 in Seat height 815 mm 32 1 in Wheelbase 1440 mm 56 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3037 mm 119 6 in Weight Curb weight FZ09E 188 kg 414 lb FZ09EC 189 kg 417 lb Maximum load FZ09E 177 kg 390 lb FZ09EC 176 kg 388 lb ...

Page 37: ...on system Wet sump Engine oil quantity Quantity disassembled 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 40 L 2 54 US qt 2 11 Imp qt With oil filter cartridge replacement 2 70 L 2 85 US qt 2 38 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer r...

Page 38: ...mm 1 4248 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 720 35 820 mm 1 4063 1 4102 in Limit 35 620 mm 1 4024 in Base circle diameter Exhaust 27 978 28 078 mm 1 1015 1 1054 in Limit 27 878 mm 1 0976 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Tensioning system Automatic Valve valve seat valve guide Valve clearance col...

Page 39: ...00 N 19 58 22 43 kgf 43 16 49 46 lbf Installed compression spring force exhaust 162 00 186 00 N 16 52 18 97 kgf 36 42 41 81 lbf Spring tilt intake 1 7 mm 0 07 in Spring tilt exhaust 1 6 mm 0 06 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston t...

Page 40: ...de 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate 1 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 7 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 2 pcs Clutch pl...

Page 41: ...FZ09E 1RC1 00 FZ09EC 1RC5 10 Throttle position sensor Resistance 1 20 2 80 k Output voltage at idle 0 63 0 73 V Accelerator position sensor Resistance 1 08 2 52 k Output voltage 0 63 0 73 V Air induction system Reed valve bending limit 0 4 mm 0 02 in Solenoid resistance 20 24 Idling condition Engine idling speed 1100 1300 r min CO AI system OFF exhaust pipe 1 50 3 50 Intake vacuum 30 5 34 5 kPa 22...

Page 42: ...l BRIDGESTONE S20F Manufacturer model DUNLOP D214F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model BRIDGESTONE S20R Manufacturer model DUNLOP D214 Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Loading condition FZ09E 90 1...

Page 43: ...m 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 18 mm 1 50 in Specified brake fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 32 0 Center to lock angle right 32 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 137 0 mm 5 39 in Fork spring free length 300 3 m...

Page 44: ... mm 7 08 in Spring rate K1 99 96 N mm 10 19 kgf mm 570 77 lbf in Spring stroke K1 0 0 60 0 mm 0 00 2 36 in Enclosed gas air pressure STD 980 kPa 9 8 kgf cm2 139 4 psi Spring preload adjusting positions Minimum 1 Standard 4 Maximum 7 Rebound damping adjusting positions Minimum 3 turn s out Standard 1 1 2 turn s out Maximum Adjusting screw fully turned in With the adjusting screw fully turned in Dri...

Page 45: ...ulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate charging current 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 0 W 55 0 W 1 Auxiliary light 12 V 5 0 W 2 Tail brake light LED Front turn si...

Page 46: ...vel po sition 484 0 536 0 Oil level switch resistance minimum level po sition 114 0 126 0 Fuel sender unit Sender unit resistance full 9 0 11 0 Sender unit resistance empty 213 0 219 0 Fuel injection sensor Crankshaft position sensor resistance 228 342 Gy B Intake air pressure sensor output voltage 3 57 3 71 V 101 3 kPa Intake air temperature sensor resistance 5400 6600 0 C 32 F 290 390 80 C 176 F...

Page 47: ...ELECTRICAL SPECIFICATIONS 2 12 Spare fuse 2 0 A ...

Page 48: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0...

Page 49: ...olt M8 6 See TIP Generator rotor bolt M12 1 75 Nm 7 5 m kgf 54 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Oil pump bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump driven sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil pump cover screw M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Water pump housing cover bolt M6 1 10 Nm 1 0 ...

Page 50: ... sprocket cover bolt M6 3 8 Nm 0 8 m kgf 5 8 ft lbf Generator cover bolt M6 8 12 Nm 1 2 m kgf 8 7 ft lbf Generator cover bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Main gallery bolt M16 2 8 Nm 0 8 m kgf 5 8 ft lbf Sub gallery plug M14 1 6 Nm 0 6 m kgf 4 3 ft lbf Clutch cable holder bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Timing chain cover bolt M6 8 12 Nm 1 2 m kgf 8 7 ft lbf Starter clutch bolt M8 3 32 Nm...

Page 51: ...M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Oil filler cap M20 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Starter motor assembly bolt M5 2 5 Nm 0 5m kgf 3 6 ft lbf Starter motor insulator nut M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Throttle position sensor screw M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Accelerator position sensor bolt M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Clutch cable and adjust nut M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Throttle ...

Page 52: ...m 2 0 m kgf 14 ft lbf 2 Tighten the bolts further to reach the specified angle 175 185 TIP Crankcase bolt main journal 1 Lubricate the bolt threads and both sides of the washers with engine oil 2 Tighten the bolts to 25 Nm 2 5 m kgf 18 ft lbf in the order shown in the illustration 3 Fully loosen the bolt 1 and then tighten the bolt again to the specified torque shown below Repeat this one by one u...

Page 53: ...mbly nut upper M10 1 44 Nm 4 4 m kgf 32 ft lbf Rear shock absorber assembly nut lower M10 1 44 Nm 4 4 m kgf 32 ft lbf Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Swingarm bracket left and swingarm bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Swingarm bracket right and swingarm bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Chain puller adjusting locknut M8 2 1...

Page 54: ... tank bracket assembly bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank cap bolt M5 4 6 Nm 0 6 m kgf 4 3 ft lbf Air scoop stay and frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket assembly and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Seat bracket and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Seat lock assembly and battery box bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front wheel axle ...

Page 55: ...de M6 4 0 8 Nm 0 08 m kgf 0 59 ft lbf Front brake lever pivot bolt M6 1 1 0 Nm 0 10 m kgf 0 72 ft lbf Front brake lever pivot nut M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Front brake light switch screw M4 1 1 2 Nm 0 12 m kgf 0 87 ft lbf Brake pedal nut M8 1 30 Nm 3 0 m kgf 22 ft lbf Rear brake master cylinder lock nut M8 1 18 Nm 1 8 m kgf 13 ft lbf Rear brake caliper bolt front M12 1 27 Nm 2 7 m kgf 20 ft l...

Page 56: ...he lower ring nut to 18 Nm 1 8 m kgf 13 ft lbf Thermostat assembly bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Fuel rail bolt M6 2 5 Nm 0 5 m kgf 3 6 ft lbf Air scoop bolt M6 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Canister bolt for California only M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Canister bracket bolt for Califor nia only M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Item Thread size Q ty Tightening torque Remarks ...

Page 57: ...tems and stem ends intake and exhaust Crankshaft big ends Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Balancer shaft journals Generator rotor assembly Water pump impeller shaft Oil pump rotors inner and outer Oil pump assembly Oil cooler bolts Oil filter cartridge union bolt Oil nozzle O rings or Main gallery bolt O ring or Oil cooler sub gallery O ring or Drive axle sub g...

Page 58: ...grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant Steering bearings seal lip and ball race lip Tube guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts and clutch cable end Swingarm collar outer surface oil seal lip Pivot shaft Swingarm pivot bush outer surface oil ...

Page 59: ...shaft joint rod moving parts Front wheel oil seal left and right Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Caliper bracket slide pins and or retaining bolts Lubrication point Lubricant LS LS LS LS LS LS LS ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 1 3 4 5 11 12 13 13 14 15 16 17 13 7 8 9 10 10 10 10 6 2 ...

Page 61: ...Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Drive axle 8 Main axle 9 Shift fork upper 10 Mission shower 11 Crankshaft 12 AC magneto 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil level switch 2 Oil filter cartridge union bolt 3 Oil filter cartridge 4 Crankshaft ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 4 7 7 8 9 5 6 2 3 1 ...

Page 65: ...BRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 4 5 6 2 3 1 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Main gallery bolt ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 6 5 3 2 7 4 1 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Balancer shaft 2 Crankshaft 3 Main axle 4 Shift fork guide bar shift fork C side 5 Drive axle 6 Sub gallery bolt 7 Shift fork ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 9 8 7 6 3 3 2 5 4 1 ...

Page 71: ...36 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil passage to the timing chain tensioner 5 Oil passage to the cylinder head 6 Oil passage to the clutch chamber 7 Oil return passage from the cylinder head 8 Crankshaft 9 Main gallery ...

Page 72: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20420 COOLING SYSTEM DIAGRAMS 1 1 2 3 ...

Page 73: ...COOLING SYSTEM DIAGRAMS 2 38 1 Water pump 2 Thermostat 3 Radiator ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 39 1 2 3 4 5 6 ...

Page 75: ...COOLING SYSTEM DIAGRAMS 2 40 1 Water jacket 2 Thermostat 3 Radiator 4 Water pump 5 Oil cooler 6 Coolant reservoir ...

Page 76: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING Handlebar top view ...

Page 77: ... A When installing the rubber cover silicone water or soapy water may be applied to the inside of the rubber cover B Detailed drawing of around the front brake master cylinder C Straight line parallel to the front brake master cyl inder reservoir cap D 3 13 E Center of the metal fitting for the front brake hose ...

Page 78: ...CABLE ROUTING 2 43 Handlebar front view ...

Page 79: ...d with the clamp G Fasten the horn lead to the stay with the clamp so that the mating section faces downward H Align the horn lead and the brake hose with the brake hose protector and fasten them to the stay with the clamp I Fasten the brake hose and the horn lead with the headlight clamp J Clamp the wire harness and then fasten it to the stay Hook the either catch of the clamp onto the stay K Out...

Page 80: ...CABLE ROUTING 2 45 Radiator front side view and right side view ...

Page 81: ...or inlet hose so that the tip of the hose contacts the rib of the water jacket joint H Install the radiator inlet hose with its yellow paint mark facing downward I Point the hose clamp installation bolt upward J Install the radiator inlet hose up to the base of the bend in the radiator pipe K Install the radiator inlet hose with its white paint mark facing inward L Install the radiator hose up to ...

Page 82: ...CABLE ROUTING 2 47 Fuel tank left and bottom view ...

Page 83: ...e white paint mark faces the rearward B Install the clip so that the end is on the paint mark Do not put it on the clip spool guard Point the end to the rear and store it inside to the fuel hose C Align the fuel pump positioning to the inner panel marking visual guide during installation D Insert the fuel tank breather hose up to the section where the fuel tank pipe increases in diameter Install i...

Page 84: ...CABLE ROUTING 2 49 Canister for California only ...

Page 85: ...ter E Face the white paint mark on the hose upward F Install the hose up to the base of the bend in the hose fitting of canister G Route the fuel tank drain hose between the canis ter and the frame H Install the fuel tank breather hose to the rollover valve making sure that the fuel tank breather hose contacts the rollover valve I To fuel tank J Point the end of the clip toward right Make sure not...

Page 86: ...CABLE ROUTING 2 51 Air filter case and throttle body top view and left side view ...

Page 87: ...at the tip touches the pipe of the cylinder head Install the breather hose on the white paint mark side to the engine Install the breather hose so that the white paint mark is in the rear of the vehicle and parallel to the cylinder head mating surfaces Install the clip so that the end is in the rear of the vehicle and parallel to the cylinder head mating surfaces C Install the ECU harness by stori...

Page 88: ...CABLE ROUTING 2 53 Air cut off valve left side view ...

Page 89: ...ve so that the tip of the hose con tacts the air filter case B Insert the protrusion on the radiator fan cover into the hole in the air cut off valve holder C Point the end of the clip for the air induction sys tem hose air cut off valve to reed valve cover 2 3 forward D Point the end of the clip for the air induction sys tem hose air filter case to air cut off valve to the left E Point the end of...

Page 90: ...CABLE ROUTING 2 55 Frame and engine right side view ...

Page 91: ...racket guide I Route the rear brake light switch lead outside brake fluid reservoir hose J It does not matter whether the O2 sensor lead or the rear brake light switch lead is on top bottom in the area shown in the illustration K Connect the radiator fan motor coupler L Insert the rubber bracket for the headlight relay so that it touches the rib of the air scoop stay on the vehicle M Install the f...

Page 92: ...CABLE ROUTING 2 57 Frame and engine left side view ...

Page 93: ...el tank drain hose and breather hose with the bending edge of the hose and then install them Face the clamp opening to the rearward H 30 50 mm 1 18 1 97 in I Point the tips of fuel tank drain hose and breather hose as shown in the illustration J Place the stator coil assembly lead so that bare copper wires do not protrude from the boots K Route the intake air temperature sensor lead above the thro...

Page 94: ...CABLE ROUTING 2 59 Frame top view ...

Page 95: ... fasten it with tape B Insert the clamp into the fuel rail hole C Fold back the injector lead 1 by the coupler and then fasten it with tape D Connect the sub lead to the injector coupler 2 Fasten the injector coupler on the wire harness side with tape E For the air cut off valve lead ignition coil lead 3 and fuel injector lead 3 it does not matter which is routed above the others F Route the coola...

Page 96: ...CABLE ROUTING 2 61 Frame top view ...

Page 97: ...coupler C Fasten the wire harness side of the oil level switch lead to the battery box D Fasten the rear brake light switch lead on the wire harness with tape E Fasten the sidestand switch lead of the wire har ness to the battery box F Route the negative battery lead inside to the branch of the O2 sensor lead and the rear brake light switch lead and through between the wire harness and the frame F...

Page 98: ...CABLE ROUTING 2 63 Frame top view ...

Page 99: ...he turn signal hazard relay in the battery box D Install the clamp into the hole in the battery box E Connect each rear turn signal coupler to the cou pler with the same color After connecting the license plate light connector store the turn signal light coupler left right furthest to the bottom of the vehicle After connecting the other couplers store them below the tail brake light lead F Route t...

Page 100: ...CABLE ROUTING 2 65 Front brake right side view and left side view ...

Page 101: ...t the brake pipe touches the projection on the brake caliper Install brake hose from the master cylinder so that it aligned with the direction of the brake pipe to the right brake caliper E Install the brake pipe so that it contacts the projec tion on the brake caliper F Face the catch of the clamp backward and then close the clamp until three clicks or more are heard G Same for three clamps H Ins...

Page 102: ...CABLE ROUTING 2 67 Rear brake ...

Page 103: ...n in the illustra tion B Make sure to install the clamp all the way in the rear frame C Fasten the protector of the brake hose with the clamp Install the mating section on the top of the vehicle D Make sure to install the clamp all the way in the swingarm assembly E Install the brake pipe so that it aligned with the cut out in the caliper ...

Page 104: ...CABLE ROUTING 2 69 ...

Page 105: ...E REAR BRAKE PADS 3 13 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 13 CHECKING THE FRONT BRAKE HOSES 3 14 CHECKING THE REAR BRAKE HOSE 3 14 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 15 CHECKING THE WHEEL BEARINGS 3 16 CHECKING THE SWINGARM OPERATION 3 16 LUBRICATING THE SWINGARM PIVOT 3 16 ADJUSTING THE DRIVE CHAIN SLACK 3 16 LUBRICATING THE DRIVE CHAIN 3 17 CHECKING AND ADJUSTING THE STEERING HEAD ...

Page 106: ...6 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 27 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 27 CHECKING AND LUBRICATING THE CABLES 3 28 CHECKING THE THROTTLE GRIP 3 28 CHECKING AND CHARGING THE BATTERY 3 29 CHECKING THE FUSES 3 29 REPLACING THE HEADLIGHT BULB 3 29 ADJUSTING THE HEADLIGHT BEAM 3 30 ...

Page 107: ... the service EAS1RC1301 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check conditi...

Page 108: ...eplace if necessary 8 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel bearings Check bearings for smooth operation Replace if necessary 10 Swingarm pivot bearings Check operation and for excessive play Moderately repack with lith ium soap based grease Every 32000 mi 50000 km 11 Drive chain Check chain slack alignment and condition Adjust ...

Page 109: ...Sidestand switch Check operation and replace if necessary 20 Front fork Check operation and for oil leakage Replace if necessary 21 Shock absorber assembly Check operation and for oil leakage Replace if necessary 22 Rear suspension link pivots Check operation Correct if necessary 23 Engine oil Change warm engine before draining 24 Engine oil filter cartridge Replace 25 Cooling system Check hoses f...

Page 110: ...Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 2 Remove Ignition coils Spark plugs NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 3 Check Spark plug type Incorrect Change...

Page 111: ...head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 9 3 Remove Timing mark accessing bolt 1 Crankshaft end cover 2 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the generator rotor with the generator rotor cover mark b TIP TDC on the compression stroke can be f...

Page 112: ...osition of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measured valve clearance 0 25 mm 0 010 in 0 25 mm 0 010 in 0 20 mm 0 008 in 0 05 mm 0 002 in c Check the thickness of the current valve pad ...

Page 113: ...P Refer to CAMSHAFTS on page 5 9 Lubricate the camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshafts marks with the camshaft cap marks Turn the crankshaft counterclockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the...

Page 114: ...ronization 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 3 Remove Caps 1 4 Install Vacuum gauge 1 5 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 6 Check Thro...

Page 115: ... throttle body synchronization can not be adjusted using the bypass air screw clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Stop the engine and remove the measuring equipment 3 Install Caps 4 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer...

Page 116: ...ontrol unit 1 Air filter case cover 2 Refer to GENERAL CHASSIS on page 4 1 3 Check Air filter element 1 Air filter seal Damage Replace TIP Replace the air filter element every 37000 km 24000 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Air filter case cover ECU engine control unit NOTICE ECA14401 Never ope...

Page 117: ...rking properly Check the brake system Refer to FRONT BRAKE on page 4 20 and REAR BRAKE on page 4 32 TIP Drive on the dry road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake fluid l...

Page 118: ...the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever hold er WARNING EWA1RC1304 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of ...

Page 119: ...s no brake drag 2 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 27 EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicator grooves 1 almost disap peared Replace the brake pads as a set Refer to REAR BRAKE on page 4 32 EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTE...

Page 120: ...hen release the brake lever or brake pedal i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 WARNING EWA13110 After bleeding ...

Page 121: ...nger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately Tire air pressure measured on cold tires Loading...

Page 122: ...eck Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 10 and CHECKING THE REAR WHEEL on page 4 17 EAS1RC1309 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM on page 4 67 2 Check Swingarm excessive play Refer to SWINGARM on page 4 67 EAS1RC1320 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seals Collars Refer to...

Page 123: ...There should be no clearance between the ad justing block and adjusting bolt c Tighten the wheel axle nut to specification d Tighten the locknuts to specification EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the vehicle is u...

Page 124: ...moves smoothly c Loosen the lower ring nut 6 completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 59 e Install the rubber wash...

Page 125: ...AS21380 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position c Tighten both locknuts d Make sure the installed shift rod length is within specific...

Page 126: ...ement Repair Refer to FRONT FORK on page 4 48 EAS1RC1315 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload WARNING EWA1RC1303 Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability NOTICE ECA135...

Page 127: ...NG THE REAR SHOCK ABSORBER ASSEMBLY on page 4 64 3 Check Rear shock absorber assembly operation Rear suspension link pivots Push down seat on the vehicle several times and check if the rear shock absorber assem bly rebounds smoothly Rough movement Repair Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 63 EAS1RC1316 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the v...

Page 128: ...d the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Direction a Spring preload...

Page 129: ...level wait a few minutes until the oil has settled EAS20791 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 Gasket 3 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following pr...

Page 130: ...ark a Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffl...

Page 131: ...distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler...

Page 132: ...slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 2 Remove Coolant reservoir bolts 1 Coolant reservoir cover 2 Coolant reservoir 3 Collars 4 3 Remove Coolant reservoir cap 1 4 Drain Coolant from the coolant reservoir 5 Remove Water pump...

Page 133: ...ll Coolant reservoir with the recommended coolant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then turn it off 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 25 TIP Before checking the coolant level wait a few minutes until the coolant has settled EAS1RC1313 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer ...

Page 134: ...fer to HANDLEBAR on page 4 44 2 Check Throttle grip movement Rough movement Lubricate or replace the defective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right 3 Check Throttle grip free play a Out of specifi...

Page 135: ...USES Refer to CHECKING THE FUSES on page 8 93 EAS21790 REPLACING THE HEADLIGHT BULB 1 Remove Headlight unit side cover bolts 1 TIP Lift up the headlight unit 2 and then remove it from the headlight stay 3 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb cover 1 4 Unhook Headlight bulb holder 1 5 Remove Headlight bulb 2 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flamm...

Page 136: ...dlight coupler 1 10 Install Headlight unit 1 TIP Install the headlight unit as shown 11 Install Headlight unit side cover bolts EAS21810 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally TIP To adjust the headlight beam horizontally in sert a crosshead screwdriver into the hole a and turn the adjust...

Page 137: ...PERIODIC MAINTENANCE 3 31 1 b c ...

Page 138: ...PERIODIC MAINTENANCE 3 32 ...

Page 139: ...SC 4 18 FRONT BRAKE 4 20 INTRODUCTION 4 25 CHECKING THE FRONT BRAKE DISCS 4 25 REPLACING THE FRONT BRAKE PADS 4 26 REMOVING THE FRONT BRAKE CALIPERS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 29 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 30 CHECKING THE FRONT BRAKE MASTER CYL...

Page 140: ...TALLING THE STEERING HEAD 4 62 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 64 DISPOSING OF A REAR SHOCK ABSORBER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE CONNECTING ARM AND RELAY ARM 4 64 INSTALLING THE RELAY ARM 4 65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 SWINGARM 4 67 REMOVING THE SWINGARM 4...

Page 141: ...IS Removing the seat and battery Order Job Parts to remove Q ty Remarks 1 Rider seat 1 2 Battery band 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery 1 6 Spacer 1 1 2 3 3 4 5 6 2 2 Nm 0 22 m kgf 1 6 ft Ibf ...

Page 142: ...Rear side cover left 1 2 Rear side cover right 1 3 Seat bracket 1 4 Tail brake light coupler 1 Disconnect 5 Tail brake light 1 6 License plate light connector 2 Disconnect 7 Rear turn signal light coupler 2 Disconnect 8 Mudguard assembly 1 1 2 3 4 5 6 6 7 8 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 143: ...t 1 4 Turn signal position light coupler right 1 Disconnect 5 Auxiliary light coupler 1 Disconnect 6 Headlight coupler 1 Disconnect 7 Headlight assembly 1 8 Headlight unit cover 1 9 Meter assembly 1 10 Meter assembly coupler 1 Disconnect 11 Meter bracket 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 6 7 8 9 10 0 8 Nm 0 08 m kgf 0 59 ft Ibf 1 3 Nm 0 13 m kgf 0 94 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m...

Page 144: ...oop and fuel tank cover Order Job Parts to remove Q ty Remarks 1 Air scoop left 1 2 Air scoop right 1 3 Fuel tank cover 1 4 Fuel tank mole left 1 5 Fuel tank mole right 1 1 2 3 4 5 5 1 5 Nm 0 15 m kgf 1 1 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf ...

Page 145: ...op into the hole d b Install the air scoop bolt and quick fastener screws and then tighten the bolts to specifi cation 2 Install Air scoop right 1 a Insert the projection a on the air scoop into the grommet b and insert the projection c on the air scoop into the hole d b Install the air scoop bolt and quick fastener screws and then tighten the bolts to specifi cation EAS1RC1404 INSTALLING THE FUEL...

Page 146: ...GENERAL CHASSIS 4 6 2 Install Fuel tank mole right 1 a Install the hole a in the fuel tank mole onto the projection b on the air scoop stay 1 a b 1 a b ...

Page 147: ...Fuel tank Refer to FUEL TANK on page 7 1 1 ECU engine control unit 1 2 ECU coupler 2 Disconnect 3 Air filter case cover 1 4 Air filter element 1 5 Air filter case joint clamp screw 3 Loosen 6 Air induction system hose 1 Disconnect 7 Cylinder head breather hose 1 Disconnect 8 Air filter case 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 6 7 8 2 8 Nm 0 28 m kgf 2 0 ft Ibf 3 3 10 1 6 Nm 0 16 m kgf 1 2 ft Ibf...

Page 148: ... Reflector 2 2 Front brake caliper 2 3 Wheel axle pinch bolt 1 Loosen 4 Wheel axle 1 5 Front wheel 1 6 Collar 2 7 Front brake disc 2 2 4 5 6 7 6 7 3 2 5 5 18 Nm 1 8 m kgf 13 ft Ibf LT 35 Nm 3 5 m kgf 25 ft Ibf LT 18 Nm 1 8 m kgf 13 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 65 Nm 6 5 m kgf 47 ft Ibf 1 1 ...

Page 149: ...FRONT WHEEL 4 9 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 1 2 3 1 2 ...

Page 150: ... Wheel bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21922 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not att...

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

Page 152: ...ned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS 1 Install ...

Page 153: ...eck that wheel axle end a is flush with front folk surface b and then tighten the wheel axle pinch bolt If end a is not flush with surface b align the ends manually or with a plastic ham mer 6 Install Front brake calipers WARNING EWA13500 Make sure the brake hose is routed properly Recommended lubricant Lithium soap based grease Wheel axle 65 Nm 6 5 m kgf 47 ft lbf Wheel axle pinch bolt 23 Nm 2 3 ...

Page 154: ...r Refer to REAR BRAKE on page 4 32 1 Locknut 2 Loosen 2 Adjusting bolt 2 Loosen 3 Wheel axle nut 1 4 Washer 1 5 Wheel axle 1 6 Adjusting block left 1 7 Adjusting block right 1 8 Rear wheel 1 9 Brake caliper bracket 1 1 2 1 2 3 4 5 6 7 8 9 16 Nm 1 6 m kgf 12 ft Ibf 150 Nm 15 m kgf 108 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf ...

Page 155: ...ve Q ty Remarks 1 Rear brake disc 1 2 Bracket 1 3 Rear wheel sprocket 1 4 Collar 1 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Collar 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 1 2 3 3 4 5 7 8 9 10 11 5 6 30 Nm 3 0 m kgf 22 ft Ibf LT 6 80 Nm 8 0 m kgf 58 ft Ibf ...

Page 156: ...REAR WHEEL 4 16 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 2 3 1 4 ...

Page 157: ... rear wheel forward and remove the drive chain from the rear wheel sprocket EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seal Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 10 EAS22091 CHECKING THE REAR WHEEL 1 Check Wheel axle Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on pa...

Page 158: ...SEMBLING THE REAR WHEEL 1 Install Wheel bearings Oil seal Refer to ASSEMBLING THE FRONT WHEEL on page 4 11 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FR...

Page 159: ...e caliper Rear brake caliper bolts 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 16 7 Tighten Wheel axle nut Rear brake caliper bolts WARNING EWA13500 Make sure the brake hose is routed properly TIP When tightening the wheel axle nut there should be no clearance a between the adjust ing block 1 and adjusting bolt 2 Recommended lubricant Lithium soap based grease b a...

Page 160: ...s to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Reflector 1 6 Front brake caliper 1 7 Bleed screw 1 1 2 3 4 5 6 7 35 Nm 3 5 m kgf 25 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf ...

Page 161: ...iaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch lead connector 2 Disconnect 6 Front brake light switch 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 1 2 3 4 5 6 7 8 9 10 11 S 10 Nm 1 0 m kgf 7 2 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf 1 5 Nm 0 15 ...

Page 162: ...FRONT BRAKE 4 22 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 S BF BF ...

Page 163: ...dure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 13 1 Brake hose union bolt 1 2 Brake hose gasket 1 3 Brake hose 2 4 Brake hose gasket 2 5 Reflector 1 6 Front brake caliper 1 1 2 3 4 5 35 Nm 3 5 m kgf 25 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 6 ...

Page 164: ...wing procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 1 2 3 4 5 6 6 7 5 6 6 7 7 7 8 S S BF S BF S 5 Nm 0 5 m kgf 3 6 ft Ibf ...

Page 165: ... Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is sta...

Page 166: ... ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the ot...

Page 167: ...AKE SYSTEM on page 3 13 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22361 DISASSEMBLING ...

Page 168: ...y Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22411 ASSEMBLING THE FRONT BRAKE CALIPERS WARNING EWA13621 Before installation all internal brake com ...

Page 169: ...e specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter ...

Page 170: ...y Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir diaphragm holder 2 Cracks damage Replace Brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA1352...

Page 171: ...WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinde...

Page 172: ...emoving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 LT S S S S ...

Page 173: ...luid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir holder 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Rear brake light switch coupler 1 Disconnect 11 Right footrest assembly 1 12 Wire guide 1 110 Nm 11 m kgf 80 ft Ibf 55 Nm 5 5 m kgf 40 ft Ibf 3 ...

Page 174: ...remove Q ty Remarks 13 Brake pedal 1 14 Rear brake master cylinder assembly 1 15 Rear brake light switch 1 55 Nm 5 5 m kgf 40 ft Ibf 3 8 Nm 0 38 m kgf 2 8 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 13 14 15 LT 30 Nm 3 0 m kgf 22 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 110 Nm 11 m kgf 80 ft Ibf ...

Page 175: ... 35 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 S BF BF ...

Page 176: ...REAR BRAKE 4 36 Removing the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 LT S S ...

Page 177: ...arts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 S S S BF ...

Page 178: ...disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 5 Adjust Brake disc runout Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 6 ...

Page 179: ...brake caliper bolts NOTICE ECA1RC1416 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 6 Check Brake pedal operation Soft or spongy feeling Bleed the br...

Page 180: ...Remove the brake caliper piston dust seal and brake caliper piston seal EAS22642 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstructi...

Page 181: ... Brake hose 2 Brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 41 NOTICE ECA1RC1402 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad insulators Brake pad shims onto t...

Page 182: ...l Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 13 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP To collec...

Page 183: ... deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake 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 lock NOTI...

Page 184: ...rip end 2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 15 Upper handlebar holder 2 16 Handlebar 1 17 Lower handlebar holder 2 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Nm 1 7 m kgf 12 ft Ibf 40 Nm 4 0 m kgf 29 ft Ibf 2 0 Nm 0 20 m kgf 1 4 ft Ibf 26 Nm 2 6 m kgf 19 ft Ibf 17 Nm 1 7 m kgf 12...

Page 185: ... weaken it EAS22931 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 NOTICE ECA1RC1407 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn the handlebar all t...

Page 186: ...of slit on the clutch lever holder with the punch mark a on the handlebar 8 Install Handlebar grip 1 Grip end 2 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Side the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP Th...

Page 187: ... 10 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 28 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 Left handlebar switch screw 2 0 Nm 0 20 m kgf 1 4 ft lbf Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Clutch lever free play 10 0 15 0 mm 0 39 0 59 in T R a b ...

Page 188: ...oth of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 8 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 1 2 3 4 5 10 Nm 1 0 m kgf 7 2 ft Ibf 26 Nm 2 6 m kgf 19 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf ...

Page 189: ...rks 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Dust seal 1 8 Oil seal clip 1 9 Outer tube 1 10 Oil seal 1 11 Washer 1 12 Outer tube bushing 1 13 Inner tube bushing 1 14 Damper rod assembly bolt 1 15 Copper washer 1 16 Damper rod assembly 1 17 Inner tube 1 LT ...

Page 190: ...t 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 8 Dust seal 1 9 Oil seal clip 1 10 Outer tube 1 11 Oil seal 1 12 Washer 1 13 Outer tube bushing 1 14 Inner tube bushing 1 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 LT ...

Page 191: ...h bolts 3 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS1RC1413 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Locknut 4 a Press down on the spacer with the fork spring compressor 5 b Install the rod ...

Page 192: ...r rod assembly the right side is used for the rebound operation Pay atten tion not to mistake the right and left TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt EAS23011 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not...

Page 193: ... with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Oil seal Oil seal clip Dust seal Copper washer O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 NOTICE ECA1RC1406 Allow the damper rod assembly to slide slowly...

Page 194: ...ace of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 Recommended oil Suspension oil 01 1 New New New New New 1 2 3 4 5 6 Fork seal ...

Page 195: ...rk 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly be cause the fork oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual Fork seal driver 90...

Page 196: ...od assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller attach ment Level left 147 mm 5 8...

Page 197: ...A c Install the locknut all the way onto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B i Remove the rod pu...

Page 198: ...fork leg to the vehicle and tightening the lower bracket pinch bolts EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bo...

Page 199: ...n page 4 1 Handlebar Refer to HANDLEBAR on page 4 44 Front fork legs Refer to FRONT FORK on page 4 48 1 Protector 1 2 Rivet 1 3 Coupler cover assembly 1 4 Clamp 1 5 Main switch coupler 2 Disconnect 6 Wire harness clamp 1 Disconnect 7 Horn lead connector 2 Disconnect 8 Horn 1 9 Front brake hose 1 10 Headlight stay 1 11 Horn bracket 1 FWD 6 7 9 10 8 110 Nm 11 m kgf 80 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 200: ...Lock washer 1 16 Upper ring nut 1 17 Rubber washer 1 18 Lower ring nut 1 19 Lower bracket 1 20 Bearing cover 1 21 Lower bearing dust seal 1 22 Upper bearing 1 23 Lower bearing 1 FWD 110 Nm 11 m kgf 80 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 52 Nm 5 2 m kgf 38 ft Ibf 1st 18 Nm 1 8 m kgf 13 ft Ibf 2nd 7 Nm 0 7 m kgf 5 1 ft Ibf 12 13 14 15 16 17 18 19 20 21 23 22 ...

Page 201: ...h Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the be...

Page 202: ... 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 18 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 48 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem nu...

Page 203: ... ENGINE REMOVAL on page 5 3 1 Connecting arm lower nut bolt 1 1 2 Relay arm nut collar bolt 1 1 1 3 Rear shock absorber assembly upper nut washer bolt 1 1 1 4 Rear shock absorber assembly lower nut washer bolt 1 2 1 5 Rear shock absorber assembly 1 6 Connecting arm upper nut bolt 1 1 7 Connecting arm 2 8 Relay arm 1 9 Collar oil seal bearing 1 2 2 10 Collar oil seal bearing 2 4 2 61 Nm 6 1 m kgf 4...

Page 204: ...rom its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Connecting arm lowe...

Page 205: ...sembly upper nut Relay arm bolt Relay arm nut Connecting arm lower bolt Connecting arm lower nut TIP Install the rear shock absorber assembly upper bolt relay arm bolt and connecting arm lower bolt from the left When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly with the rebound damping adjusting screw facing the left side of the vehicle...

Page 206: ...REAR SHOCK ABSORBER ASSEMBLY 4 66 Rear shock absorber assembly upper nut 44 Nm 4 4 m kgf 32 ft lbf Relay arm nut 61 Nm 6 1 m kgf 44 ft lbf Connecting arm lower nut 55 Nm 5 5 m kgf 40 ft lbf T R ...

Page 207: ... 5 3 Chain Refer to CHAIN DRIVE on page 4 70 1 Connecting arm lower nut 1 2 Connecting arm lower bolt 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Washer 1 6 Swingarm 1 7 Drive chain guard 1 8 Drive chain guide 1 9 Rear fender 1 10 Dust cover 4 11 Collar 3 12 Oil seal 4 13 Bearing 4 110 Nm 11 m kgf 80 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 13 7 Nm 0 7 m kgf 5 1 ft Ibf 10 55 Nm 5 5 m kgf 40 ft Ibf 7 Nm 0 7 m...

Page 208: ...e to side If the swingarm has side to side play check the spacer bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collar bearings and dust covers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 71 Swingarm EAS23361 CHECKING THE SWINGARM 1...

Page 209: ...olt Connecting arm lower nut Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 63 and REAR WHEEL on page 4 14 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 16 Recommended lubricant Lithium soap based grease Installed depth a 2 0 mm 0 08 in Installed depth b 9 0 mm 0 35 in Installed depth c 0 5 1 5 mm 0 02 0 06 in Installed depth d 7 0 mm 0 28 in Installed ...

Page 210: ...Remarks 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive chain guide 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive sprocket 1 9 Drive chain 1 1 2 3 4 5 6 14 Nm 1 4 m kgf 10 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 7 8 9 95 Nm 9 5 m kgf 69 ft Ibf E 1 8 Nm 0 8 m kgf 5 8 ft Ibf LT E ...

Page 211: ...pins and the length c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length a of the 15 link section of the drive chain using the following formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that th...

Page 212: ... Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sproc...

Page 213: ...ide of the connecting link 3 and inside of the connecting plate 1 is 14 1 14 3 mm 0 56 0 65 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installing make s...

Page 214: ... ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 5 0 15 0 mm 0 20 0 59 in ...

Page 215: ...HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 GENERATOR AND STARTER CLUTCH 5 30 REMOVING THE GENERATOR 5 32 REMOVING THE STARTER CLUTCH 5 32 CHECKING THE STARTER CLUTCH 5 32 INSTALLING...

Page 216: ... PAN 5 55 CHECKING THE OIL STRAINER 5 55 INSTALLING THE OIL PAN 5 55 CRANKCASE 5 56 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 60 REMOVING THE CONNECTING RODS AND PISTONS 5 61 CHECKING THE CYLINDER AND PISTON 5 61 CHECKING THE PISTON RINGS 5 62 CHECKING THE PISTON PIN 5 63 CHECKING THE CONNECTING RODS 5 63 INSTALLING THE...

Page 217: ...CHECKING THE SHIFT DRUM ASSEMBLY 5 81 CHECKING THE TRANSMISSION 5 81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 81 INSTALLING THE TRANSMISSION 5 82 ...

Page 218: ...ension 2 5 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA1RC1501 To prevent sparking the plug remove all ig nition coil couplers and fuel injector cou plers before cranking the engine TIP The difference in compression pressure be twe...

Page 219: ...er to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Piston valves cylin der head gasket pos sibly defective Repair Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf T R ...

Page 220: ...ts to remove Q ty Remarks 1 O2 sensor coupler bracket 1 2 O2 sensor coupler 1 Disconnect 3 Muffler assembly 1 4 Exhaust gasket 3 5 Muffler protector 1 1 2 3 4 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 221: ... rail Refer to THROTTLE BODIES on page 7 5 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Right footrest assembly Refer to REAR BRAKE on page 4 32 Drive sprocket Refer to CHAIN DRIVE on page 4 70 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Negative battery lead 1 Disconnect 4 Ignition coil coupler 3 Disconnect 5 Coolant tempe...

Page 222: ...ds and hoses Order Job Parts to remove Q ty Remarks 8 Gear position sensor coupler 2 Disconnect 9 Crankshaft position sensor coupler 1 Disconnect 10 Stator coil coupler 1 Disconnect 8 9 7 Nm 0 7 m kgf 5 1 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 10 ...

Page 223: ...eft front upper side 1 1 1 4 Adapter bolt left 1 5 Engine mounting bolt rear lower side engine mounting nut rear lower side 1 1 6 Engine mounting bolt rear upper side engine mounting nut rear upper side 1 1 7 Engine 1 8 Engine mounting adjust bolt 3 1 2 3 4 5 6 7 8 45 Nm 4 5 m kgf 33 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 45 Nm 4 5 m kgf 33 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 45 ...

Page 224: ...t left 5 temporarily tighten 5 Install Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 TIP Temporarily tighten the engine mounting bolts 6 8 6 Tighten Engine mounting adjust bolt front 1 TIP Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench Make sure that the flange on the eng...

Page 225: ...rear upper side 12 11 Tighten Engine mounting bolt right front upper side 10 Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 12 Tighten Adapter bolt left 5 Adapter bolt right 9 Engine mounting adjust bolt rear 7 Nm 0 7 m kgf 5 1 ft lbf Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wre...

Page 226: ...tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 1 2 3 4 5 6 13 Nm 1 3 m kgf 9 4 ft Ibf 10 Nm 1 0 m kgf...

Page 227: ...asket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 7 Camshaft cap 1 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 12 Timing chain bolt 1 13 Dowel pin 1 14 Timing chain guide intake side 1 15 Timing chain 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10 Nm 1 0 m kgf 7 2 ft Ibf 24 Nm 2 4 m kgf 17 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf E E LT 10 Nm 1 0 ...

Page 228: ...hen the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Camshaft cap 1 Intake camshaft cap 2 Exhaust camshaft cap 3 NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaus...

Page 229: ...camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft wrench 90890 04162 YM 04162 Camshaft lobe dimensions Lobe height Intake 36 290 36 390 mm 1 4287 1 4327 in Limit 36 190 mm 1 4248 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 720 35 820 mm 1 4063 1...

Page 230: ...shaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide intake side 1 Timing chain guide top side 2 Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check T...

Page 231: ...cover mark b a Turn the crankshaft counterclockwise b When piston 1 is at BTDC125 on the com pression stroke align the BTDC125 mark a on the generator rotor with the generator rotor cover mark b 3 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 NOTICE ECA1RC1505 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose ...

Page 232: ...NOTICE ECA1RC1506 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 7 Tighten Camshaft cap bolts 1 TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working f...

Page 233: ...ioner rod by hand remove the hexagon wrench and then insert the hexagon wrench 2 Parts No 1RC 12228 00 into the timing chain ten sioner rod d Install the timing chain tensioner gasket 3 the timing chain tensioner 4 and the timing chain tensioner bolts 5 on the cylinder block TIP Face the section b of the gasket inward e Tighten the timing chain tensioner bolts to the specified torque f Screw the h...

Page 234: ...punch mark c on the cam shaft is aligned with the camshaft cap align ment mark d Out of alignment Adjust Refer to the installation steps above 12 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 13 Install Timing mark accessing bolt 1 Crankshaft end cover 2 14 Install Timing chain guide top side Cylinder head cover gasket 1 Cylinder head cover...

Page 235: ...he cylinder head gasket 1 to the cylinder head cover cut off the a section 15 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf 1 a T R 1 ...

Page 236: ...er to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide exhaust side 1 1 2 3 4 5 8 E 4 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 1st 16 Nm 1 6 m kgf 12 ft Ibf 2nd 10 Nm 1 0 m kgf 7 2 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 237: ...se 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 Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded...

Page 238: ...ylinder head bolts 1 8 Cylinder head bolts 9 12 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as shown and torque them in 2 stages 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 14 Cylinder head bolt 1 8 1st 25 Nm...

Page 239: ... 12 4 Intake valve spring retainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 15 Exhaust valve 6 16 Exhaust valve stem seal 6 17 Exhaust valve spring seat 6 18 Exhaust valve guide 6 1 ...

Page 240: ... and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each ...

Page 241: ...ling the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve gui...

Page 242: ... cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have...

Page 243: ...ck and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear i...

Page 244: ... VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant b Installed length Installed compression spring force intake 192 00 220 00 N 19 58 22 43 kgf 43 16 49 46 lbf Installed compression spring force exhaust 162 00 186 00 N 16 52 18 97 kgf 36 42 41 81 lbf ...

Page 245: ...d the valve spring compressor attachment 3 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter b Smaller pitch New Valve spring compressor 9...

Page 246: ...VALVES AND VALVE SPRINGS 5 29 TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 247: ... oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Holder fuel tank overflow hose and breather hose 1 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil lead holder 1 8 Stator coil assembly stator coil crankshaft posi tion sensor 1 1 2 3 5 6 7 8 75 Nm 7 5 m kgf 54 ft Ibf 32 Nm 3 2 m...

Page 248: ...lutch idle gear shaft 1 14 Starter clutch idle gear 1 15 Crankshaft end cover 1 16 Timing mark accessing bolt 1 17 Water pump outlet pipe 1 9 12 15 16 17 75 Nm 7 5 m kgf 54 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 15 Nm 1 5 m kgf 11 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 14 Nm 1 4 m kgf 10 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf E E 13 14 E 10 11 E 3 LT 6 3 LT 12...

Page 249: ...nerator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check St...

Page 250: ...ave holder 3 tighten the starter clutch bolts EAS24500 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer with engine oil Lubricate the generator r...

Page 251: ...ator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 41 Yamaha bond No 1215 Three bond No 1215 90890 85505 Generator cover bolt 1 12 Nm 1 2 m kgf 8 7 ft lbf LOCTITE Generator cover bolt 2 12 Nm 1 2 m kgf 8 7 ft lbf New T R 1 2 2 2 ...

Page 252: ... 1 Air scoop Fuel tank cover Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Negative battery lead 1 Disconnect 3 Starter motor 1 1 2 3 12 Nm 1 2 m kgf 8 7 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 253: ...RIC STARTER 5 36 Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Rear cover 1 ...

Page 254: ...ssembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set 6 Check Gear teeth Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 0...

Page 255: ...ear cover 1 Starter motor yoke 2 Front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Negative battery lead 2 Starter motor bolts 3 TIP Install the negative battery lead as shown in the illustration 2 Connect Starter motor lead Starter motor bolt 12 Nm 1 2 m kgf 8 7 ft ...

Page 256: ...fer to CHANGING THE ENGINE OIL on page 3 23 1 Clutch cable 1 Disconnect 2 Cover 1 3 O2 sensor coupler bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil filler cap 1 1 2 3 4 5 6 7 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf 6 7 ...

Page 257: ... 40 Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 1 2 3 4 5 6 7 8 E ...

Page 258: ...1 5 Friction plate 1 7 6 Clutch plate 8 7 Friction plate 2 2 Green paint mark 8 Clutch boss nut 1 9 Conical spring washer 1 10 Washer 1 11 Clutch boss 1 12 Thrust plate 1 13 Clutch housing 1 14 Oil pump drive chain 1 15 Bearing 1 16 Spacer 1 17 Thrust plate 1 18 Thrust plate 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 LT 125 Nm 12 5 m kgf 90 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 5 7 5 E E E E ...

Page 259: ...mp driven sprocket 1 Refer to OIL PUMP on page 5 50 3 Remove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 4 Remove Friction plate 1 1 5 Remove Clutch plate 1 Friction plate 2 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 1 2 1 1 2 1 3 Universal clutch...

Page 260: ...of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set Friction plate 1 thickn...

Page 261: ...eplace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gea...

Page 262: ...ge wear Replace EAS25240 INSTALLING THE CLUTCH 1 Install Oil pump drive chain 1 Clutch housing 2 TIP Install the oil pump drive chain onto the oil pump drive sprocket a 2 Install Thrust plate Clutch boss 1 Washer Conical spring washer 2 Clutch boss nut 3 TIP Install the conical spring washer on the main axle with the OUT mark a facing away from the vehicle While holding the clutch boss 1 with the ...

Page 263: ...nto the pull rod Position the pull rod so that the teeth a face towards the hole b Then install the clutch cover 5 Install Dowel pins Clutch cover gasket Clutch cover Cover TIP Apply engine oil onto the bearing Tighten the clutch cover bolts in stages and in a crisscross pattern 6 Install Pull lever TIP Install the pull lever with the O mark facing to ward lower side When installing the pull lever...

Page 264: ...CLUTCH 5 47 7 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in a b ...

Page 265: ...to CLUTCH on page 5 39 Shift arm Refer to CHAIN DRIVE on page 4 70 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 3 4 5 6 7 8 9 10 11 LT E 22 Nm 2 2 m kgf 16 ft Ibf E 1 2 12 13 E E ...

Page 266: ...hift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with lithi um soap based grease Lubricate...

Page 267: ...oving the oil pump Order Job Parts to remove Q ty Remarks Clutch cover Refer to CLUTCH on page 5 39 1 Oil pump driven sprocket 1 2 Oil pump assembly 1 1 2 10 Nm 1 0 m kgf 7 2 ft Ibf 15 Nm 1 5 m kgf 11 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf LT ...

Page 268: ... Remarks 1 Oil pump cover 1 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Circlip 1 Hold down the washer when removing the circlip 7 Washer 1 8 Spring 1 9 Relief valve 1 10 Dowel pin 2 E 1 2 3 4 5 6 7 8 9 10 3 8 Nm 0 38 m kgf 2 8 ft Ibf 10 ...

Page 269: ... outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and out er rotor clearance c Out of specification Replace the defective part s 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 1 2 Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump...

Page 270: ...on Refer to CHECKING THE OIL PUMP on page 5 52 EAS25030 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 Oil pump driven sprocket 3 NOTICE ECA1RC1508 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly TIP 1RC mark of the oil pump driven sprocket is in stalled at oil pump side Install the oil pump drive chain onto the oil pump driven spr...

Page 271: ...r to FUEL TANK on page 7 1 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch lead holder 1 3 Oil level switch 1 4 O2 sensor lead holder 1 5 Oil pan 1 6 Oil pan gasket 1 7 Oil strainer 1 1 2 3 4 5 6 7 LT 13 LT 43 Nm 4 3 m kgf 31 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 ...

Page 272: ...mage Replace Contaminants Clean with solvent EAS25050 INSTALLING THE OIL PAN 1 Install Gasket Oil pan 1 Oil level switch 2 Engine oil drain bolt 3 WARNING EWA12820 Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with lithi um soap based grease Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil level switch bolt 10 Nm ...

Page 273: ...n page 5 54 1 Oil filter cartridge 1 2 Oil filter cartridge union bolt 1 3 Gear position sensor 1 4 Speed sensor 1 5 Clutch cable holder 1 6 Lower crankcase 1 7 Dowel pin 3 1 2 3 4 5 6 7 7 6 2 2 4 2 11 7 E E E E LT E LT LT 24 Nm 2 4 m kgf 17 ft Ibf 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 60 1st 3rd 15 Nm 1 5 m kgf 11 ft Ibf 2nd 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 60 1st 3rd 18 Nm 1 8 m kgf...

Page 274: ...haft journal bearings from the lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out wi...

Page 275: ...in bolt 18 M6 65 mm 2 56 in bolts 15 16 M6 65 mm 2 56 in bolt 26 M6 50 mm 1 97 in bolts 17 19 21 23 25 27 30 M6 40 mm 1 57 in bolt 22 7 Tighten Crankcase bolts 1 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA1RC1504 If the crankcase bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Inst...

Page 276: ...Tighten the bolts in the tightening sequence cast on the crankcase Crankcase bolts 9 14 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 15 30 10 Nm 1 0 m kgf 7 2 ft lbf 8 1 2 3 4 5 6 7 8 T R 22 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ...

Page 277: ...ove Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 56 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 E 1 2 3 4 6 7 8 9 10 M M E E 3 20 Nm 2 0 m kgf 14 ft Ibf 1st Specified angle 2nd 175 185 E 5 ...

Page 278: ...during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the othe...

Page 279: ...IP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 Taper limit maximum of D1 or D2 maxi mum of D5 or D6 Out of round limit maximum of D1 D3 or D5 minimum of ...

Page 280: ...ide diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set EAS1RC1504 CHECKING THE CONNECTING RODS 1 Measure Crankshaft pin to big end bearing clearance Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 ...

Page 281: ...region tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them ont...

Page 282: ... specified angle 175 185 WARNING EWA13400 If the connecting rod bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again NOTICE ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle j After the installation check that the section shown a...

Page 283: ...ing rod TIP Be sure to reinstall each big end bearing in its original place Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Make sure that the projection c on the con necting rod cap faces the same direction as the Y mark d on the connecting rod 2 Tighten Connecting rod bolts NOTICE ECA1RC1509 Tighten the connecting rod bolts using...

Page 284: ...e current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the connect in...

Page 285: ...ton up to the cylinder 9 Install Connecting rod caps Connecting rod bolts TIP Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and seats 10 Tighten Connecting rod bolts 1 TIP Tighten ...

Page 286: ...h a new one and perform the procedure again NOTICE ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface WARNING EWA1RC1503 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from st...

Page 287: ...Lower crankcase Refer to CRANKCASE on page 5 56 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 61 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzle 3 1 2 3 4 5 6 7 E 2 3 E 7 E E ...

Page 288: ... pin surfaces Bearing surfaces Scratches wear Replace the crankshaft 3 Measure Crankshaft journal to crankshaft jour nal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crank shaft journal to crankshaft journal bearing clearance and prevent engine damage the crankshaft journal b...

Page 289: ...lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re p...

Page 290: ...damage the balancer shaft journal bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft j...

Page 291: ...elect replacement balancer shaft journal bearings 4 Select Balancer shaft journal bearings J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration If J1 J2 are the same use the sa...

Page 292: ...Balancer journal upper bearings into the upper crankcase Balancer journal lower bearings into the lower crankcase TIP Align the projections a on the balancer journal bearings 1 with the notches b in the crank cases Be sure to install each balancer journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the balancer shaft match mark b 1...

Page 293: ...SE on page 5 56 1 Drive axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift drum retainer 2 6 Shift fork guide bar 2 7 Shift fork L 1 8 Shift fork R 1 9 Shift drum assembly 1 10 Shift fork C 1 11 Main axle assembly 1 12 Bearing 1 1 2 3 4 5 6 7 8 9 10 11 E LT 12 Nm 1 2 m kgf 8 7 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf LT LT E E E E E 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf LT E 12 ...

Page 294: ... pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 9 10 12 15 13 14 7 8 6 5 4 3 2 1 11 E M M M M M M ...

Page 295: ...lar 1 5 5th wheel gear 1 6 Circlip 1 7 Washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 12 4th wheel gear 1 13 Collar 1 14 Washer 1 15 Circlip 1 16 6th wheel gear 1 17 Circlip 1 18 Washer 1 19 Collar 1 20 2nd wheel gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 M M E M E M M M M M M ...

Page 296: ...TRANSMISSION 5 79 Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 21 Collar 1 22 Bearing 1 23 Circlip 1 24 Drive axle 1 21 M M E M E 22 23 24 M M M M M M ...

Page 297: ...ontinue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Bearing 1 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WAR...

Page 298: ... drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Ch...

Page 299: ...the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer EAS26350 INSTALLING THE TRANSMISSION 1 Install Bearing 1 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing housing 2 A Main axle B...

Page 300: ... Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Touch the protrusion d on the shift fork guide bar to the side of the shift drum retainer Make sure that the drive axle ...

Page 301: ...G THE RADIATOR 6 2 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 302: ...oolant reservoir 1 4 Coolant reservoir cap 1 5 Radiator cap 1 6 Radiator fan motor coupler 1 Disconnect 7 Radiator hose cylinder head to radiator 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator outlet hose 1 Disconnect 10 Radiator 1 11 Radiator fan cover 1 12 Radiator fan 1 13 Radiator stay 1 1 2 3 4 5 6 7 8 9 10 LT 10 Nm 1 0 m kgf 7 2 ft Ibf 0 5 Nm 0 05 m kgf 0 37 ft Ibf 5 Nm 0 5 m kgf...

Page 303: ...Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator b Apply 122 7 kPa 1 23 kgf...

Page 304: ...DIATOR 6 3 pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 305: ...o ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Radiator inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil cooler union bolt 1 5 Washer 1 6 Oil cooler 1 7 Water jacket joint 1 10 Nm 1 0 m kgf 7 2 ft Ibf E 35 Nm 3 5 m kgf 25 ft Ibf LT 1 2 3 4 5 6 7 ...

Page 306: ... O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase After installing the oil cooler union bolt bend the tab c of the washer 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on p...

Page 307: ...ts to remove Q ty Remarks Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Radiator outlet hose 1 2 Water pump inlet hose 1 3 Oil cooler outlet hose 1 Disconnect 4 Thermostat assembly 1 1 2 3 4 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 308: ...ling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 2 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 1 ...

Page 309: ...0 WATER PUMP Removing the water pump Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 1 2 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 310: ...r Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Water pump driven gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft 1 8 Mechanical seal 1 9 Bearing 1 10 Oil seal 1 E E 1 2 3 4 5 6 7 8 9 10 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 311: ... EAS26541 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing 3 TIP Install the oil seal with...

Page 312: ...nical seal is dirty clean it 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 NOTICE ECA1RC1602 Make sure the mechanical seal impeller side is flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanical seal ...

Page 313: ...REMOVING 7 8 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 REPLACING THE THROTTLE BODIES 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 10 CHECKING THE FUEL PRESSURE 7 11 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE ACCELERAT...

Page 314: ...l tank breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 9 Wire harness assembly intake air temperature sensor 1 10 Air scoop stay left 1 11 Wire harness assembly headlight relay fuse box 1 radiator fan motor coupler 1 12 Air scoop stay right 1 1 2 3 4 5 5 6 7 8 9 10 11 12 2 4 2 2 2 2 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm...

Page 315: ...ver Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister purge hose hose joint to canister 1 2 Fuel tank breather hose fuel tank to rollover valve 1 3 Rollover valve 1 4 Fuel tank breather hose rollover valve to canis ter 1 5 Canister 1 6 Canister breather hose 1 7 Canister bracket 1 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 7 6 ...

Page 316: ...e it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an up right position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do ...

Page 317: ...e fuel tank side NOTICE ECA1RC1708 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connect...

Page 318: ...7 1 For California only 1 Fuel hose 1 2 Intake air pressure sensor 1 coupler 1 Disconnect 3 Intake air pressure sensor 2 coupler 1 Disconnect 4 Accelerator position sensor coupler 1 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Throttle cable accelerator cable 1 Disconnect Black 8 Throttle cable decelerator cable 1 Disconnect 9 Throttle bo...

Page 319: ...6 2 Hose joint 2 3 Canister purge hose 5 For California only 4 Hose joint 3 For California only 5 Intake air pressure sensor 2 1 6 Intake air pressure sensor 1 1 7 Throttle position sensor 1 8 Accelerator position sensor 1 3 5 Nm 0 35 m kgf 2 5 ft Ibf 1 1 1 3 5 6 7 8 3 5 Nm 0 35 m kgf 2 5 ft Ibf 4 3 3 4 2 ...

Page 320: ...hrottle bodies Throttle body joint Refer to THROTTLE BODIES on page 7 5 1 Fuel rail 1 2 Injector 3 3 Injector coupler 2 Disconnect 4 Injector lead 1 5 Injector lead coupler 1 Disconnect 6 Wire harness 1 7 Adapter 1 3 5 6 1 4 2 3 2 5 Nm 0 5 m kgf 3 6 ft Ibf 7 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 321: ...ilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF and disc...

Page 322: ...ings a c Hold the throttle valves in the open position WARNING EWA1RC1704 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA1RC1703 Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools to open the throttle valves or to keep them in the open position Do not...

Page 323: ... page 3 8 5 Place the vehicle on a suitable stand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS1RC1705 INSTALLING THE INJECTORS NOTICE ECA1RC1702 Always use new O rings When installing the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails or O rings Be careful not to ...

Page 324: ...c tors EAS1RC1709 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat air scoop and fuel tank cover Refer to GENERAL CHASSIS on page 4 1 b Remove the fuel tank bolt and hold up the fuel tank c Disconnect the fuel hose 1 from the fuel pump Refer to REMOVING THE FUEL TANK on page 7 3 WARNING EWA1RC1702 Cover fuel hose connection with a cloth when disconnecting them Residual pres...

Page 325: ...place it 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 107 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sensor screws b Check that the throttle valves are fully closed c Turn the main switch to OFF d Connect the throttle position se...

Page 326: ...nnect the throttle cables to the throttle bod ies f Simultaneously press and hold the SE LECT button 1 and RESET button 2 turn the main switch to ON and continue to press the buttons for 8 seconds or more TIP dIAG appears on the display g Simultaneously press the SELECT button 1 and RESET button 2 for 2 seconds or more to set the diagnostic mode TIP The diagnostic code number 1 appears on the disp...

Page 327: ... display value is not 10 24 adjust the acceler ator position sensor angle q Turn the throttle grip to the fully open position r Check the meter display value If the meter display value is not 95 109 adjust the accel erator position sensor angle s Repeat steps h to r until the meter display values are within the specified ranges t If the meter display values are not within the specified ranges afte...

Page 328: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM 1 2 3 2 3 4 4 ...

Page 329: ...AIR INDUCTION SYSTEM 7 16 1 Air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 330: ... RADIATOR on page 6 1 1 Air cut off valve coupler 1 Disconnect 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air induction system hose air cut off valve to reed valve cover 1 4 Air induction system hose air filter case to air cut off valve 1 5 Air cut off valve 1 6 Air cut off valve holder 1 7 Reed valve cover 1 8 Reed valve assembly 1 1 9 Reed valve plate 1 10 Reed valve c...

Page 331: ...perature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve assembly 3 Measure Reed valve bending limit a Out of s...

Page 332: ... that the open side turns to the exhaust side of the en gine Install the reed valve assembly 2 so that the open side turns to the intake side of the engine 3 Install Reed valve cover A Reed valve assembly 1 B Reed valve assembly 2 C Exhaust side Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE 1 c d d A C B C T R ...

Page 333: ...DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 35 DIAGNOSTIC MODE 8 36 YAMAHA DIAGNOSTIC TOOL 8 37 TROUBLESHOOTING DETAILS 8 38 FUEL PUMP SYSTEM 8 81 CIRCUIT DIAGRAM 8 81 TROUBLESHOOTING 8 83 ELECTRICAL COMPONENTS 8 85 CHECKING THE SWITCHES 8 8...

Page 334: ...E FUEL SENDER 8 104 CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT 8 105 CHECKING THE OIL LEVEL WARNING LIGHT 8 105 CHECKING THE SPEED SENSOR 8 105 CHECKING THE RADIATOR FAN MOTORS 8 106 CHECKING THE COOLANT TEMPERATURE SENSOR 8 106 CHECKING THE THROTTLE POSITION SENSOR 8 107 CHECKING THE ACCELERATOR POSITION SENSOR 8 107 CHECKING THE THROTTLE SERVO MOTOR 8 108 CHECKING THE AIR INDUCTION SYSTEM ...

Page 335: ......

Page 336: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 337: ... system fuse 18 Joint connector 19 Joint coupler 20 Relay unit 23 ECU engine control unit 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 Spark plug 33 Crankshaft position sensor 38 Lean angle sensor 58 Gear position sensor 61 Sidestand switch 62 Right handlebar switch 64 Start engine stop switch ...

Page 338: ...spark However the engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position sensor is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position sensor is closed and the sides tand is down the sidestand switch circuit is open 1 Battery 2 Main fuse 3 Ma...

Page 339: ...K 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 100 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 100 NG Replace the ignition coils OK 6 Check the crankshaft position sen sor Refer to CHECKING THE...

Page 340: ...OK 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 99 NG Replace the relay unit OK 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 101 NG Replace the lean angle sensor OK 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU Refe...

Page 341: ...IGNITION SYSTEM 8 6 ...

Page 342: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 343: ...y 14 Engine ground 15 Fuel injection system fuse 16 Starter relay 17 Starter motor 18 Joint connector 19 Joint coupler 20 Relay unit 21 Starting circuit cut off relay 58 Gear position sensor 61 Sidestand switch 62 Right handlebar switch 64 Start engine stop switch 70 Clutch switch ...

Page 344: ...losed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions...

Page 345: ...IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN DLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Gear position sensor neutral circuit 11 Diode 12 Starter relay 13 Starter motor ...

Page 346: ...r operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 102 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 37 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 97 NG Replace t...

Page 347: ... Replace the sidestand switch OK 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the clutch switch OK 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the right handlebar switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wiring...

Page 348: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 349: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 13 Battery 14 Engine ground ...

Page 350: ...E BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 102 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 102 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on ...

Page 351: ...CHARGING SYSTEM 8 16 ...

Page 352: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 353: ...or 19 Joint coupler 23 ECU engine control unit 45 Meter assembly 47 Meter light 54 High beam indicator light 69 Left handlebar switch 74 Pass switch 75 Dimmer switch 78 Front right turn signal position light 79 Front left turn signal position light 80 Headlight 81 Auxiliary light 82 License plate light 83 Tail brake light 84 Headlight relay ...

Page 354: ...and signal Refer to CHECKING THE FUSES on page 8 93 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 89 NG The dimmer...

Page 355: ...the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 NG Properly connect or repair the lighting sys tem s wiring OK Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 93 ...

Page 356: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 357: ... indicator light 52 Engine trouble warning light 53 Coolant temperature warning light 55 Left turn signal indicator light 56 Right turn signal indicator light 57 Oil level switch 58 Gear position sensor 59 Fuel sender 62 Right handlebar switch 65 Hazard switch 66 Front brake light switch 67 Rear brake light switch 68 Turn signal hazard relay 69 Left handlebar switch 71 Horn 72 Horn switch 73 Turn ...

Page 358: ... FUSES on page 8 93 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair th...

Page 359: ...signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the front turn signal position light bulbs rear turn signal light bulbs and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 92 NG Replace the front turn signal position light bulb s rear turn signal light bulb s sock et s or both OK...

Page 360: ...ck the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 99 NG Replace the relay unit OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the oil level switch OK 2 Check the en...

Page 361: ...eed sensor OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 93 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 106 NG Replace the coolant temperature sensor...

Page 362: ...COOLING SYSTEM 8 27 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 363: ...28 3 Main switch 4 Main fuse 7 Radiator fan fuse 9 Ignition fuse 13 Battery 14 Engine ground 18 Joint connector 23 ECU engine control unit 35 Coolant temperature sensor 85 Radiator fan motor relay 86 Radiator fan motor ...

Page 364: ...CHECKING THE SWITCHES on page 8 89 NG Replace the main switch OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 106 NG Replace the radiator fan motor s OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 97 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SE...

Page 365: ...COOLING SYSTEM 8 30 ...

Page 366: ...FUEL INJECTION SYSTEM 8 31 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 367: ...tion system solenoid 32 O2 sensor 33 Crankshaft position sensor 34 Intake air temperature sensor 35 Coolant temperature sensor 36 Intake air pressure sensor 1 37 Intake air pressure sensor 2 38 Lean angle sensor 39 Speed sensor 40 Throttle servo motor 41 Accelerator position sensor 42 Throttle position sensor 43 Yamaha diagnostic tool connector 44 Yamaha diagnostic tool coupler 45 Meter assembly 4...

Page 368: ...emains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the side of the start en gine stop switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has ...

Page 369: ...ng light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the condit...

Page 370: ...o OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 38 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors...

Page 371: ...de number by pressing the SE LECT and RESET buttons TIP The diagnostic code number appears on the display 1 70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1 second or longer...

Page 372: ...ayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool However the diagnostic tool cannot be used to freely change the basic vehicle functions such as ad justing the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap 1 and then connect the Yamaha diagnostic tool 2 to the coupler Yamaha diagnostic to...

Page 373: ...stic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 8 36 Fault code No 12 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of malfunction and check Maintenanc...

Page 374: ...sensor Check for looseness or pinching Check the gap 0 85 mm 0 0335 in between the crankshaft position sensor and the generator rotor Improperly installed sensor Reinstall or replace the sensor Refer to GENERATOR AND STARTER CLUTCH on page 5 30 Crank the engine Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective crankshaft position senso...

Page 375: ...t or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between intake air pressure sensor 1 coupler and ECU coupler pin...

Page 376: ...ine is cranking Check the intake air pressure sensor 1 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 109 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 14 Item Intake air pre...

Page 377: ...d weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking C...

Page 378: ... Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire ha...

Page 379: ...throttle valves are fully closed A value of 9 23 is indicated When the throttle valves are fully open A value of 94 108 is indi cated An indicated value is out of the specified range Replace the throttle position sensor Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 7 7 Malfunction in ECU Replace the ECU Refer to REPLAC...

Page 380: ... pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Connection of relay unit cou pler Check the locking condition of the coupler Disconn...

Page 381: ... air pressure sensor 2 volt age differ greatly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 04 03 Meter display Displays the intake air pressure Procedure Shift the transmission into gear extend the sidestand and then operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK 04 Meter display D...

Page 382: ...ecute the diagnostic mode Code No 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg Displayed value is incorrect Check the intake air pres sure sensor 2 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSO...

Page 383: ...upler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short cir...

Page 384: ...ually measured air temperature with the meter display value Item Probable cause of malfunction and check Maintenance job Confirmation of service completion 1 Connection of intake air tem perature sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler sec...

Page 385: ...d Fault code number is dis played Go to item 5 5 Defective intake air tempera ture sensor Execute the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temper ature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENSOR on page 8 1...

Page 386: ...re harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Start the engine warm it up and then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played Service is finished Fault code ...

Page 387: ...ort circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 04 Meter display Displays the intake air pressure Procedure Shift the transmission into gear extend the sidestand and then operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK Item Probable cause of malfunction and check Maint...

Page 388: ...essure sensor 2 coupler and ECU coupler pink white pink white Between intake air pressure sensor 2 coupler and joint connector blue blue black blue black blue Between joint connector and ECU coupler blue blue black blue black blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of intake air press...

Page 389: ...t above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor 2 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 109 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is di...

Page 390: ...ine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Defective intake air pressure sensor 2 Execute the diagnostic mode Code No 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft abo...

Page 391: ...ion and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 101 Turn the main switch to ON then to OFF and then back to ON Fault...

Page 392: ...nd let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between cylinder 1 ignition coil coupler and ECU cou pler orange orange Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is fin...

Page 393: ...nd locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins b...

Page 394: ...ircuit detected in the primary lead of the cylinder 3 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 32 Actuation Actuates the cylinder 3 ignition coil five times at one second intervals Illuminates the engine trouble warning light Procedure Check that a spark is ge...

Page 395: ... 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective cylinder 3 ignition coil Measure the primary coil resistance of the cylinder 3 ignition coil Replace if out of specifica tion Refer to CHECKING THE IGNITION COILS on page 8 100 Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Se...

Page 396: ... 3 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Execute the diagnostic mode Code Nos 36 37 38 No operating sound Go to item 3 Operating sound Go to item 7 3 Defective injector 1 2 and or injector 3 Measure the inje...

Page 397: ...n angle sensor open or short circuit detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 08 Meter display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunction and check Maintenance job Confirmation of service completion 1 Connection of...

Page 398: ...ck blue Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 101 Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis ...

Page 399: ...cking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indi cated value increases Value increases Go to item 6 and delete the fault code Value does not incr...

Page 400: ...on page 8 93 Go to item 6 and delete the fault code 6 Delete the fault code Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 19 mi h The fault code can also be deleted by activating the diagnostic mode and select ing diagnostic code number 63 Fault code No 42 Item A Speed sensor no norma...

Page 401: ...dication Go to item 2 When the transmission is in gear with the clutch lever squeezed and the sidestand is retracted ON Incorrect indication Go to item 2 in section C for the clutch switch 2 Connection of neutral switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connec...

Page 402: ...eutral ON When the transmission is in gear with the clutch lever released OFF Correct indication Go to item 9 Incorrect indication Go to item 5 5 Defective relay unit Check the relay unit Refer to CHECKING THE RELAY UNIT DIODE on page 8 99 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Correct indica...

Page 403: ...to 30 km h 19 mi h The fault code can also be delete by activating the diag nostic mode and selecting diagnostic code number 63 Fault code No 42 Item A Speed sensor no normal signals are received from the speed sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21...

Page 404: ...ndication Go to item 2 2 Clutch lever adjustment Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 Execute the diagnostic mode Code No 21 When the clutch lever is released OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 3 3 Connection of clutch switch coupler Check the locking condition of the coupler Disconnect the coupler and chec...

Page 405: ...s released OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 6 6 Defective relay unit Check the relay unit Refer to CHECKING THE RELAY UNIT DIODE on page 8 99 Execute the diagnostic mode Code No 21 When the clutch lever is released OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 7 7 Defe...

Page 406: ...oltage is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals Illuminates the engine trouble warning light Procedure Check that the relay unit is actuated five times by listening for the operating sound Item Probable cause of malfunction and check Maintenance job Confirmation of service completion 1 Connection of relay unit cou pler Check the locking co...

Page 407: ...umber is not dis played Service is finished Fault code number is dis played Go to item 4 4 Defective relay unit Execute the diagnostic mode Code No 50 No operating sound Replace the relay unit Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective relay unit Execute the diagnostic...

Page 408: ...lt code number is dis played Repeat item 1 If the same number is indi cated go to item 3 3 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of malfunction and check Maintenance job...

Page 409: ...itch to ON Check that the fault code number is not displayed Fault code No 59 Item Accelerator position sensor open or short circuit detected Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 14 15 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully open position Procedure Check with throttle grip in fully closed...

Page 410: ... harness continuity Open or short circuit Replace the wire harness Between accelerator posi tion sensor coupler and ECU coupler black blue black blue white white black black blue blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of acceler ator position sensor Check for looseness or pinching Im...

Page 411: ...ode No 15 When the throttle grip is fully closed A value of 10 24 is indicated When the throttle grip is fully open A value of 95 109 is indi cated An indicated value is out of the specified range Replace the accelerator posi tion sensor 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 60 Item YCC T drive system malfunction detected Fai...

Page 412: ...nished Fault code number is dis played Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between throttle servo motor coupler and ECU coupler yellow red yellow red yellow white yellow white Between ECU coupler and fuse box 2 electronic throttle valve fuse red white red white Turn the main switch to ON Fault code number is not dis played Service is finished Fault...

Page 413: ...nnection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harne...

Page 414: ...Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 93 Fault code No 89 Yamaha diagnostic tool Err multi function meter display Item Multi function meter signals cannot be transmitted between the ECU and the multi function meter ...

Page 415: ...FUEL INJECTION SYSTEM 8 80 ...

Page 416: ...FUEL PUMP SYSTEM 8 81 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 417: ...ch 4 Main fuse 9 Ignition fuse 13 Battery 14 Engine ground 15 Fuel injection system fuse 18 Joint connector 20 Relay unit 22 Fuel pump relay 23 ECU engine control unit 60 Fuel pump 62 Right handlebar switch 64 Start engine stop switch ...

Page 418: ...3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the main switch OK 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 89 NG Replace the right handlebar switch OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 97 NG Replace the relay unit OK 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP OPERATION on p...

Page 419: ...FUEL PUMP SYSTEM 8 84 ...

Page 420: ...ELECTRICAL COMPONENTS 8 85 EAS27973 ELECTRICAL COMPONENTS 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 421: ...ake light switch 4 Battery 5 Fuse box 2 6 Main fuse 7 Fuel injection system fuse 8 Starter relay 9 Rectifier regulator 10 Rear brake light switch 11 Gear position sensor 12 Sidestand switch 13 O2 sensor 14 Oil level switch 15 Ignition coil 16 Radiator fan motor 17 Horn ...

Page 422: ...ELECTRICAL COMPONENTS 8 87 ...

Page 423: ...n motor relay 7 Turn signal hazard relay 8 Relay unit 9 Speed sensor 10 Stator coil 11 Crankshaft position sensor 12 Coolant temperature sensor 13 Throttle servo motor 14 Accelerator position sensor 15 Throttle position sensor 16 Intake air pressure sensor 1 17 Intake air pressure sensor 2 18 Injector 19 Air induction system solenoid 20 Fuse box 1 ...

Page 424: ...ELECTRICAL COMPONENTS 8 89 EAS27981 CHECKING THE SWITCHES 2 1 3 4 5 6 7 11 12 13 8 9 10 ...

Page 425: ...tch 2 Pass switch 3 Turn signal switch 4 Horn switch 5 Clutch switch 6 Oil level switch 7 Sidestand switch 8 Hazard switch 9 Start engine stop switch 10 Drive mode switch 11 Front brake light switch 12 Main switch 13 Rear brake light switch ...

Page 426: ...ch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by There is continuity ...

Page 427: ... WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transp...

Page 428: ...OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause t...

Page 429: ... caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the elec...

Page 430: ...n full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following ...

Page 431: ...or to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu l...

Page 432: ... specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negativ...

Page 433: ...specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal haza...

Page 434: ...Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue w...

Page 435: ...on spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Pocket tester 90890 03112 Analog pock...

Page 436: ...THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the fuel tank bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resis tance 228 342 Gy B Pocket t...

Page 437: ...no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 ...

Page 438: ...rn resistance Out of specification Replace a Disconnect the horn leads from the horn ter minals b Connect the digital circuit tester to the horn terminals Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive...

Page 439: ...ification Replace the fuel pump assembly a Connect the pocket tester 10 100 to the fuel sender terminals as shown Oil level switch Oil level switch resistance maxi mum level position 484 0 536 0 Oil level switch resistance mini mum level position 114 0 126 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe Connector gray 1 Negative tester pro...

Page 440: ...n circuit 1 Check Oil level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunc tion detected in oil level switch Replace the oil level switch EAS28241 CHECKING THE SPEED SENSOR 1 Check ...

Page 441: ...19 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester 1 k to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a contai...

Page 442: ... its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 EAS29100 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle bodies WARNING EWA1RC1706 Handle the accelerator position sensor with special care Never subject the accelerator position sen sor to strong shocks If the accelerator po sition sensor is dropped replace it 2 Check A...

Page 443: ... Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor EAS28371 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester 1 to the air in ductio...

Page 444: ...NG EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester 100 to the in take air temperature sensor terminal as shown Intake air pressure sensor output volta...

Page 445: ...si tion sensor Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Result Neutral position Continuity Positive tester probe sky blue 1 Negative tester probe Sensor terminal a 1st position Continuity Positive tester probe white 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe pink 3 Negative teste...

Page 446: ...uel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket tester 10 to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance 12 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 ...

Page 447: ...D HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 EVENT CODE TABLE 9 12 ...

Page 448: ...or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary ...

Page 449: ... stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch...

Page 450: ... outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front ...

Page 451: ...d or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal hazard relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal hazard relay B...

Page 452: ...rom the O2 sensor 8 50 25 Intake air pressure sensor 2 open or short circuit detected 8 52 26 Intake air pressure sensor 2 hose system malfunction clogged or detached hose 8 54 30 Latch up detected 8 56 33 Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 ignition coil 8 56 34 Cylinder 2 ignition coil open or short circuit detected in the primary lead of...

Page 453: ... 11 21 Check with throttle valves fully closed Fully open position 96 106 Check with throttle valves fully open 03 Intake air pressure 1 Displays the intake air pressure Shift the transmission into gear extend the sides tand and then operate the throttle while pushing the side of the start engine stop switch If the display value changes the perfor mance is OK 04 Intake air pressure 2 Displays the ...

Page 454: ...oltage battery voltage Fuel system voltage Approximately 12 0 Set the start engine stop switch to and then compare the actually mea sured battery voltage with the meter display value If the actually measured bat tery voltage is low recharge the battery 13 Throttle position sensor signal 2 Fully closed position 9 23 Check with throttle valves fully closed Fully open position 94 108 Check with throt...

Page 455: ...and when the sides tand is retracted ON Clutch lever is squeezed with the transmission in gear and when the sides tand is extended OFF 60 EEPROM fault code dis play No history 00 No malfunctions detected If the self diagnosis fault code 44 is indicated the ECU is defective History exists 01 03 Cylinder fault code If more than one cylin der is defective the dis play alternates every two seconds to ...

Page 456: ...including the current malfunction that have occurred since the his tory was last erased For example if there have been three mal functions 03 is dis played To erase the history set the start engine stop switch from to 63 Malfunction code rein statement for fault code No 24 42 only No malfunction code 00 Malfunction code exists Fault code 24 42 If more than one code number is detected the display a...

Page 457: ...der 2 ignition coil five times at one second intervals Illuminates the engine trouble warning light Check that a spark is gen erated five times Connect an ignition checker 32 Cylinder 3 ignition coil Actuates the cylinder 3 ignition coil five times at one second intervals Illuminates the engine trouble warning light Check that a spark is gen erated five times Connect an ignition checker 36 Injecto...

Page 458: ...rouble warning light Check that the relay unit is actuated five times by lis tening for the operating sound 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals Illuminates the engine trouble warning light Check that the radiator fan motor relay is actuated five times by listening for the operating sound 52 Headlight relay Actuates the headlight rel...

Page 459: ...tion items listed for fault code No 19 196 Coolant temper ature sensor Brief abnormality detected a in the coolant tempera ture sensor Same as fault code 21 Perform the inspection items listed for fault code No 21 197 Intake air tem perature sensor Brief abnormality detected in the intake air tempera ture sensor Same as fault code 22 Perform the inspection items listed for fault code No 22 199 Int...

Page 460: ... between the sensor and ECU Drop in fuel pres sure Clogged fuel injec tor Fault in sensor Malfunction in ECU Malfunction in the fuel injection sys tem If a fault code is occurring respond to that first Rarely Code 241 occurs even when the system is functioning properly 242 ISC Stuck at the upper limit for adjustment During idling the adjustment is main tained at the upper limit Idling engine speed...

Page 461: ...lity to start Poor starting inabil ity to start detected No gasoline Malfunction in the fuel injection sys tem Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a fault code is occurring respond to that first Rarely Code 244 occurs even when the system is functioning properly 245 Engine stop Engine stop detected No gasoline Poorly adjusted throttle cable Poorly adjusted clu...

Page 462: ...EVENT CODE TABLE 9 15 ...

Page 463: ...t turn signal indicator light 57 Oil level switch 58 Gear position sensor 59 Fuel sender 60 Fuel pump 61 Sidestand switch 62 Right handlebar switch 63 Drive mode switch 64 Start engine stop switch 65 Hazard switch 66 Front brake light switch 67 Rear brake light switch 68 Turn signal hazard relay 69 Left handlebar switch 70 Clutch switch 71 Horn 72 Horn switch 73 Turn signal switch 74 Pass switch 7...

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Page 467: ...FZ09E FZ09EC 2014 WIRING DIAGRAM 1RC 28197 10_W D indd 1 2013 09 20 13 52 03 ...

Page 468: ...FZ09E FZ09EC 2014 WIRING DIAGRAM 1RC 28197 10_W D indd 2 2013 09 20 13 52 04 ...

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