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Yamaha FZ6-S 2004, Service Manual

The Yamaha FZ6-S 2004 Service Manual is the go-to manual for owners seeking in-depth knowledge and maintenance tips for their motorcycle. Available for free download at manualshive.com, this comprehensive manual provides step-by-step instructions and crucial information to keep your FZ6-S running smoothly and efficiently.

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ENGINE SPECIFICATIONS

SPEC

Item

Standard

Limit

Camshafts

Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions

Measurement A

Measurement B

Exhaust camshaft lobe dimensions

Measurement A

Measurement B

Max. camshaft runout

Chain drive (right)
23.008 

X

 23.029 mm (0.9058 

X

 0.9067 in)

22.967 

X

 22.980 mm (0.9042 

X

 0.9047 in)

0.028 

X

 0.062 mm (0.0011 

X

 0.0024 in)

32.45 

X

 32.55 mm (1.278 

X

 1.282 in)

24.95 

X

 25.05 mm (0.982 

X

 0.986 in)

32.45 

X

 32.55 mm (1.278 

X

 1.282 in)

24.95 

X

 25.05 mm (0.982 

X

 0.986 in)

SSS

SSS

SSS

SSS

0.08 mm
(0.0032 in)

32.40 mm
(1,276 in)
24.90 mm
(0.980 in)

32.40 mm
(1.276 in)
24.90 mm
(0.980 in)
0.06 mm
(0.0024 in)

Summary of Contents for FZ6-S 2004

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Page 3: ...FZ6 S S SERVICE MANUAL 2003 by Yamaha Motor Co Ltd First edition August 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...mprove 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 Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 5: ...he top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number i...

Page 6: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 7: ...FICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 FI 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS ...

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Page 10: ...URES 1 2 OUTLINE OF FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTION 1 4 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 11: ...GEN INFO ...

Page 12: ...TORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...perating conditions such as acceleration deceleration or operating under a heavy load Carburetors that me ter the fuel through the use of jets have been provided with various auxiliary devices so that an opti mum air fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine As the requirements for the engine to deliver more performance and cleaner exh...

Page 14: ...ke manifold only during the time the passage remains open Therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied Con versely the shorter the length of time the injector is energized injection duration the lesser the vol ume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU...

Page 15: ...e tachometer mode E is the following order ODO TRIP 1 TRIP 2 TRIP F E ODO When approximately 3 6 L of fuel remain in the fuel tank the bottom segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the display be...

Page 16: ...tton together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock ...

Page 17: ...disassembly clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 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 ...

Page 18: ...s are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways repl...

Page 19: ... Connect and disconnect sev eral times 3 Check Sall connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect Slead Scoupler Sconnector Make sure all connections are tight 5 Check Scontinuity with the pocket tester Pocket tester 90890 03112 YU 3112 SIf there is no continuity clean the terminals SWhen checking the wire harness perform steps 1 to 3 ...

Page 20: ...is used to remove the generator ro tor 90890 01701 YS 01880 A Sheave holder This tool is used to hold the generator rotor when removing or installing the generator ro tor bolt or pickup coil rotor bolt 90890 01304 YU 01304 Piston pin puller This tool is used to remove the piston pins Radiator cap tester 90890 01325 YU 24460 01 Adapter 90890 01352 YU 33984 Radiator cap tester Adapter These tools ar...

Page 21: ...ion gauge Adapter These tools are used to measure engine compression 90890 03112 YU 3112 Pocket tester This tool is used to check the electrical sys tem Oil pressure gauge 90890 03153 YU 03153 Adapter 90890 03139 Oil pressure gauge Adapter These tools are used to measure engine oil pressure 90890 03176 YM 03176 Fuel pressure adapter This tool is needed to measure fuel pressure 90890 03153 YU 03153...

Page 22: ...his tool is needed to remove and install the valve lifter 90890 04111 Valve guide remover φ4 This tool is used to remove or install the valve guides 90890 04112 Valve guide installer φ4 This tool is used to install the valve guides 90890 04113 YM 04113 Valve guide reamer φ4 This tool is used to rebore the new valve guides 90890 06754 YM 34487 Ignition checker This tool is used to check the ignitio...

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Page 24: ......

Page 25: ... 2 14 CONVERSION TABLE 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 24 COOLING SYSTEM DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 30 CABLE ROUTING 2 36 ...

Page 26: ...SPEC ...

Page 27: ... Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 095 mm 82 5 in 750 mm 29 5 in 1 215 mm 47 8 in 795 mm 31 3 in 1 440 mm 56 7 in 145 mm 5 71 in 2 800 mm 110 2 in SSS SSS SSS SSS SSS SSS SSS Weight Wet with oil and a full fuel tank Maximum load except motorcycle 207 kg 456 lb 190 kg 419 lb SSS SSS ...

Page 28: ...commended fuel Fuel tank capacity Total including reserve Reserve only Regular unleaded gasoline only 19 4 L 4 25 lmp gal 5 1 US gal 3 6 L 0 79 lmp gal 0 9 US gal SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature Relief valve opening pressure Wet sump Ref...

Page 29: ...p opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 0 L 1 76 lmp pt 2 11 US qt 93 3 X 122 7 kPa 0 93 X 1 23 kg cm2 0 93 X 1 23 bar 13 5 X 17 8 psi 300 mm 11 81 in 188 mm 7 4 in 24 mm 0 94 in 0 27 L 0 24 lmp qt 0 29 US qt Single suction centrifugal pump 86 44 31 31 1 955 SSS SSS SSS SSS SSS SSS SSS SSS 0...

Page 30: ...obe dimensions Measurement A Measurement B Max camshaft runout Chain drive right 23 008 X 23 029 mm 0 9058 X 0 9067 in 22 967 X 22 980 mm 0 9042 X 0 9047 in 0 028 X 0 062 mm 0 0011 X 0 0024 in 32 45 X 32 55 mm 1 278 X 1 282 in 24 95 X 25 05 mm 0 982 X 0 986 in 32 45 X 32 55 mm 1 278 X 1 282 in 24 95 X 25 05 mm 0 982 X 0 986 in SSS SSS SSS SSS 0 08 mm 0 0032 in 32 40 mm 1 276 in 24 90 mm 0 980 in 3...

Page 31: ...e stem runout Valve seat width Intake Exhaust 24 9 X 25 1 mm 0 9803 X 0 9882 in 21 9 X 22 1 mm 0 8622 X 0 8701 in 1 14 X 1 98 mm 0 0449 X 0 0780 in 1 14 X 1 98 mm 0 0449 X 0 0780 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 6 X 0 8 mm 0 0236 X 0 0315 in 0 6 X 0 8 mm 0 0236 X 0 0315 in 3 975 X 3 990 mm 0 1565 X 0 1571 in 3 960 X 3 975 mm 0 1559 X 0 1565 in 4 000 X 4 012 mm 0...

Page 32: ...8 in 32 5 mm 1 28 in 36 1 mm 1 42 in 69 0 X 79 0 N 7 03 X 8 05 kg 15 50 X 17 75 lb 114 0 X 132 0 N 11 62 X 13 46 kg 25 63 X 29 67 lb 160 X 184 N 16 32 X 18 76 kg 35 97 X 41 36 lb SSS SSS SSS Counter clockwise Clockwise Clockwise 35 2 mm 1 39 in 36 5 mm 1 44 in 39 7 mm 1 56 in SSS SSS SSS SSS SSS SSS 2 5_ 1 6 mm 0 06 in 2 5_ 1 7 mm 0 07 in 2 5_ 1 8 mm 0 07 in SSS SSS SSS Cylinders Cylinder arrangem...

Page 33: ...0004 X 0 0014 in 65 475 X 65 490 mm 2 5778 X 2 5783 in 4 mm 0 16 in 16 002 X 16 013 mm 0 6300 X 0 6304 in 0 5 mm 0 0197 in Intake side 15 991 X 16 000 mm 0 6296 X 0 6299 in 0 002 X 0 022 mm 0 0001 X 0 0009 in Barrel 0 90 2 45 mm 0 04 0 10 in 0 25 X 0 35 mm 0 0098 X 0 0138 in 0 030 X 0 065 mm 0 0012 X 0 0026 in Taper 0 8 2 5 mm 0 03 0 10 in 0 7 X 0 8 mm 0 0276 X 0 0315 in 0 030 X 0 065 mm 0 0012 X ...

Page 34: ...Brown 4 Green SSS SSS 0 03 mm 0 0012 in SSS SSS SSS 0 10 mm 0 0039 in SSS Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Friction plates Color code Thickness Plate quantity Color code Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Thickness Plate quantity Max warpage Clutch spring...

Page 35: ...SSS 0 02 mm 0 0008 in 0 02 mm 0 0008 in Shifting mechanism Shift mechanism type Max shift fork guide bar bending Shift drum Guide bar SSS SSS 0 05 mm 0 002 in Air filter type Oil coated paper element SSS Fuel pump Pump type Model manufacturer Output pressure Electrical 5VX DENSO 250 kPa 2 5 kg cm2 2 5 bar 36 3 psi SSS SSS SSS Throttle position sensor Resistance Output voltage at idle 4 0 X 6 0 kΩ ...

Page 36: ...heel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 M C MT5 50 Aluminum 130 mm 5 12 in SSS SSS SSS SSS SSS SSS 1 mm 0 04 in 0 5 mm 0 02 in Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 0 X 198 lb 90 X 190 kg 198 X 419 lb High speed riding Min tire tread depth Tubeless 120 70 ZR17 M C 58W BT020F GG BR...

Page 37: ...ss Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm 11 73 0 20 in SSS SSS 6 0 mm 0 24 in 16 mm 0 63 in 30 2 mm and 25 4 mm 1 19 in and 1 00 in SSS SSS SSS SSS 4 5 mm 0 18 in 0 1 mm 0 004 in 0 8 mm 0 03 in SSS SSS Rear brake Brake type Operation Brake pedal position below the bottom of the footrest bracket Recommended fluid Brake d...

Page 38: ...Quantity each front fork leg Level from the top of the inner tube with the inner tube fully compressed and without the fork spring Telescopic fork Coil spring oil damper 130 mm 5 12 in 354 0 mm 13 94 in 131 5 mm 5 18 in 347 0 mm 13 66 in 7 4 N mm 0 75 kg mm 42 25 lb in 11 8 N mm 1 20 kg mm 67 38 lb in 0 X 70 mm 0 X 2 76 in 70 X 130 mm 2 76 X 5 12 in 43 mm 1 69 in SSS No Suspension oil 01 or equiva...

Page 39: ...ad adjusting positions Minimum Standard Maximum Swingarm monocross Coil spring gas oil damper 50 mm 1 97 in 185 0 mm 7 28 in 172 0 mm 6 77 in 127 4 N mm 12 99 kg mm 727 45 lb in 0 X 50 mm 0 00 X 1 97 in No 1 200 kPa 12 kg cm2 12 bar 170 7 psi 1 3 7 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Swingarm Free play at the end of the swingarm Radial Axial SSS SSS 1 0 mm 0 04 in 1 0 mm 0 04 in Drive ...

Page 40: ...0_C 68_F SSS SSS Charging system System type Model manufacturer Normal output Stator coil resistance color A C magneto F5VX MORIC 14 V 310 W at 5 000 r min 0 22 X 0 34 Ω at 20_C 68_F W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semi conductor short circuit SH719AA SHINDENGEN SSS SSS No load regulated voltage Rectifier capacity Withstand voltage 14 1 X 14 9 V 18 A 240 V ...

Page 41: ... kW 10 mm 0 39 in 7 16 X 9 52 N 730 X 971 g 25 77 X 34 27 oz 0 0012 X 0 0022 Ω at 20_C 68_F 28 mm 1 1 in 0 7 mm 0 03 in SSS SSS SSS 3 5 mm 0 14 in SSS SSS 27 mm 1 06 in SSS Starter relay Model manufacturer Amperage Coil resistance MS5F 441 JIDECO 180 A 4 18 X 4 62 Ω at 20_C 68_F SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil resistance Plain HF 12 NIKKO 1 3 A ...

Page 42: ...l level sender Model manufacture Sender unit resistance full Sender unit resistance empty 5VX DENSO 20 X 26 Ω 134 X 140 Ω SSS SSS SSS Starting circuit cut off relay Model manufacture Coil resistance G8R 30Y S OMRON 162 X 198 Ω SSS SSS Headlight relay Radiator fan motor relay Model manufacture Coil resistance ACM33211M05 MATSUSHITA 86 4 X 105 6 Ω SSS SSS Fuel injection system relay Model manufactur...

Page 43: ...10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 ftSlb 4 3 11 22 40 61 94 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSIO...

Page 44: ... Bolt M12 1 18 1 8 13 Coolant hose drain bolt water pump Bolt M6 1 10 1 0 7 2 Radiator and frame Bolt M6 2 7 0 0 7 5 1 Radiator stay and crankcase Bolt M6 1 10 1 0 7 2 Oil pump cover Bolt M6 3 12 1 2 8 7 Oil pump Bolt M6 3 12 1 2 8 7 Oil pan Bolt M6 12 12 1 2 8 7 Oil pan center Bolt M6 1 12 1 2 8 7 Oil cooler Bolt M20 1 63 6 3 46 Engine oil drain bolt Bolt M14 1 43 4 3 31 Oil filter union bolt Bol...

Page 45: ...reather hose cover Bolt M6 4 12 1 2 8 7 Oil pipe Bolt M6 2 12 1 2 8 7 Crankshaft position sensor Bolt M6 2 10 1 0 7 2 Starter clutch Screw M8 3 32 3 2 23 Starter motor cover bolt Bolt M6 2 3 4 0 34 2 5 Clutch pressure plate Screw M6 6 8 0 0 8 5 8 Clutch boss Nut M20 1 90 9 0 65 Drive sprocket Nut M18 1 90 9 0 65 Transmission bearing housing Screw M6 3 12 1 2 8 7 Shift drum retainer Bolt M6 2 10 1 ...

Page 46: ...2 20 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence ...

Page 47: ...0 Engine mount bolts right of front side M10 55 5 5 40 See NOTE 2 Engine mount self locking nut upper M10 55 5 5 40 Engine mount self locking nut lower M10 55 5 5 40 Pivot shaft and frame M18 120 12 87 Rear shock absorber and frame M10 40 4 0 29 Rear shock absorber and rear arm M10 40 4 0 29 Seal guard and rear arm M6 7 0 7 5 1 Rear fender and rear arm M6 7 0 7 5 1 Rear brake hose holder and rear ...

Page 48: ...per bracket M8 27 2 7 20 Rear brake caliper bolt rear and rear brake caliper bracket M8 22 2 2 16 Rear wheel sprocket and rear wheel drive hub M10 100 10 72 Chain adjusting bolt lock nut M8 16 1 6 12 Rear brake hose union bolt M10 30 3 0 22 Sidestand bolt lock nut M10 46 4 6 33 Sidestand bracket and frame M10 63 6 3 46 Sidestand switch screw M5 4 0 4 2 9 Footrest bracket and frame M8 30 3 0 22 Rea...

Page 49: ... pump rotors inner and outer Oil pump housing Oil strainer Clutch pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Cylinder head cover semicircular Yamaha bond No ...

Page 50: ...pivoting point and metal to metal moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Engine mount bolts rear upper and lower Shift pedal shaft Shift...

Page 51: ...2 25 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Oil cooler COOLING SYSTEM DIAGRAMS ...

Page 52: ...2 26 COOLING SYSTEM DIAGRAMS SPEC 1 Water pump 2 Oil cooler 3 Radiator ...

Page 53: ...2 27 COOLING SYSTEM DIAGRAMS SPEC 1 Oil cooler 2 Water pump ...

Page 54: ...2 28 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Thermostat ...

Page 55: ...2 29 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART ...

Page 56: ...2 30 LUBRICATION DIAGRAMS SPEC 1 Oil level switch 2 Oil cooler 3 Relief valve LUBRICATION DIAGRAMS ...

Page 57: ...2 31 LUBRICATION DIAGRAMS SPEC 1 Oil pump 2 Exhaust camshaft 3 Intake camshaft 4 Oil strainer ...

Page 58: ...2 32 LUBRICATION DIAGRAMS SPEC 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump ...

Page 59: ...2 33 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Oil pump 3 Relief valve ...

Page 60: ...2 34 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft ...

Page 61: ...2 35 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Drive axle ...

Page 62: ...p down to the length of 1 to 5 mm 0 04 to 0 20 in C Route the horn lead by the headmost side D Pass the throttle cables wire harness lead clutch cable main switch and immobilizer lead and left handlebar switch lead in order through the frame hole from the inner side of the vehicle E Point the lead which comes from the terminal to the front side of the vehicle body 1 Left handlebar switch lead 2 Ma...

Page 63: ...inner tube Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm 0 04 to 0 20 in G Pass the throttle cables through the wire guide Route the right handlebar switch lead by the outside of the wire guide ...

Page 64: ...r hoses 2 pieces under the cover 2 E Route the crank shaft position sensor lead inner side of the radiator hose F Pull down the mark painted sections of the fuel tank breather hose fuel tank drain hose and coolant res ervoir tank breather hose to be lower than the clamp position of the muffler stay Any order to take out the fuel tank breather hose and fuel tank drain hose can be accepted G Pass th...

Page 65: ...ll the right handlebar switch lead coupler through the hole of the bracket 2 from the downside L Route the starter motor lead by the inner side of the air cut off valve hose M Pass the ignition coil leads 1 and 4 through inner side of the air cut off valve hose and then between the frame and bracket 2 CABLE ROUTING SPEC ...

Page 66: ...ll side 25 Radiator fan motor lead 26 Oil level gauge lead 27 Sidestand switch lead 28 A C magneto lead 29 Speed sensor lead 1 Main switch and immobilizer lead 2 Stay assembly 3 Left handlebar switch lead 4 Clutch cable 5 Throttle cables 6 Battery negative lead coupler 7 Starter relay lead 8 Battery negative lead 9 Fuel tank drain hose 10 Rectifier regulator 11 Turn signal relay 12 Radiator fan mo...

Page 67: ...but make sure that the leads are not crossed L Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the brack et Pull out the lead sufficiently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in upward M Clamp the rear turn signal lead and license plate light lead to the frame...

Page 68: ... the tip to be between 1 and 5 mm 0 04 and 0 20 in S To the rear turn signal light left T Pass the fuel tank drain hose through the clamp lo cated under the coolant reservoir tank U Route it behind the starter motor lead V Point the bend R section of the throttle cable pull side to the inner side horizontally It is also possible to visually check the bend R section W To the headlight lead X Point ...

Page 69: ... 24 Spark plug lead 25 Air cut off valve hose 1 Right handlebar switch lead 2 Throttle cables 3 Battery positive lead 4 Coolant reservoir tank hose 5 Battery cover 6 Connecter cover 7 Fuel tank breather hose 8 Brake fluid reservoir hose 9 Lean angle cut off switch 10 Fuse box 11 Rear turn signal light lead right 12 Rear turn signal light lead left 13 License plate light lead CABLE ROUTING SPEC ...

Page 70: ...tor lead and crank shaft posi tion sensor lead Point the projected part of the tip to the inner side of the vehicle G Pass the radiator hose coolant reservoir hose wire harness and starter motor lead in order through the lower side of the vehicle H Set the 4 pin coupler in the connector cover after wiring it I To the sidestand switch J To the speed sensor K To the A C magneto L To the oil level ga...

Page 71: ...off valve hose AL Route the spark plug lead 2 behind the air cut off valve hose CABLE ROUTING SPEC S To the license plate light T To the tail brake light U Insert the enwinding clamp of the wire harness into the hole of the rear frame V Attach the rectifier regulator lead to the clamp of the rectifier bracket W To the engine ground X To the fuel injection Y To the fuel pump Z Route the clutch cabl...

Page 72: ...M Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 AN Route the spark plug leads 2 and 3 behind the air cut off valve hose Then route the spark plug lead 3 by the front side of the spark plug lead 2 ...

Page 73: ......

Page 74: ...TLE BODIES 3 16 ADJUSTING THE ENGINE IDLING SPEED 3 18 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 19 CHECKING THE SPARK PLUGS 3 22 MEASURING THE COMPRESSION PRESSURE 3 23 CHECKING THE ENGINE OIL LEVEL 3 26 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 31 CLEANING THE AIR FILTER ELEMENT 3 32 CHECKING THE THROTTLE BODY JOINTS 3 33 CHECKING T...

Page 75: ...LACK 3 48 LUBRICATING THE DRIVE CHAIN 3 49 CHECKING AND ADJUSTING THE STEERING HEAD 3 50 CHECKING THE FRONT FORK 3 52 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 53 CHECKING THE TIRES 3 54 CHECKING THE WHEELS 3 56 CHECKING AND LUBRICATING THE CABLES 3 57 LUBRICATING THE LEVERS AND PEDALS 3 57 LUBRICATING THE SIDESTAND 3 57 LUBRICATING THE CENTERSTAND 3 57 LUBRICATING THE REAR SUSPENSION 3 58 ELEC...

Page 76: ... See page 3 22 S Replace Ǹ Ǹ 3 Valves See page 3 10 S Check valve clearance S Adjust Every 40 000 km 4 Air filter element See page 3 32 S Replace Ǹ 5 Clutch See page 3 31 S Check operation S Adjust Ǹ Ǹ Ǹ Ǹ Ǹ 6 Front brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 6 See page 3 41 43 45 S Replace brake pads Whenever worn to the limit 7 Rear brake S Check operation fluid...

Page 77: ... km and after washing the motorcycle or riding in the rain 24 Front and rear brake switches See page 3 45 See page 8 4 S Check operation Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 25 Moving parts and cables See page 3 57 S Lubricate Ǹ Ǹ Ǹ Ǹ Ǹ 26 Throttle grip housing and cable See page 3 19 S Check operation and free play S Adjust the throttle cable free play if necessary S Lubricate the throttle grip housing and cable Ǹ Ǹ Ǹ Ǹ ...

Page 78: ...3 3 SEAT CHK ADJ Order Job Part Q ty Remarks 1 Removing the seat Seat 1 Remove the parts in the order listed For installation reverse the removal procedure EAS00038 SEAT ...

Page 79: ...pler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose Fuel tank Fuel pump 1 1 1 1 1 1 1 Remove the parts in the order listed Disconnect Refer to SEAT Refer to COWLINGS There is a white paint mark on the fuel tank breather hose For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb NOTE EAS00040 FUEL TANK ...

Page 80: ...ses since there may be fuel remain ing in it Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Sfuel tank Do not set the fuel tank down so that the installa tion surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position REMOVING THE FUEL PUMP 1 Remove Sfuel pump SDo not drop the fuel pump or give it a stron...

Page 81: ...fuel pump bolts in stages in a criss cross pattern and to the specified torque INSTALLING THE FUEL TANK 1 Install Sfuel hose When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct position otherwise the fuel hose will not be properly installed 2 Install Sfuel sender coupler Sfuel pump coupler Sfuel tank breather hose Sfuel tank drain...

Page 82: ...ont cowling Rear view mirrors left and right Windshield Rear cowling Frame side cover 2 2 1 2 1 1 2 Remove the parts in the order listed Refer to SEAT Disconnect For installation reverse the removal procedure 33 Nm 3 3 mSkg 24 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb COWLINGS CHK ADJ COWLINGS ...

Page 83: ...Loosen Disconnect Disconnect Disconnect For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb Removing the air filter case Seat Front cowling inner panel left and right Fuel tank Intake temperature sensor coupler Throttle body hose Air induction system hose Clamp Crankcase breather hose Starter relay Battery negative lead Battery positive lead Battery cover Battery Air filter case...

Page 84: ...tery box Battery box bracket Ignition coil assembly 1 3 2 Remove the parts in the order listed This part has to be set properly For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb NOTE BATTERY BOX AND BATTERY BOX BRACKET ...

Page 85: ... inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sbattery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Sair filter case Refer to AIR FILTER CASE Sbattery box Sbattery box bracket Refer to BATTERY BOX AND BATTERY BOX BRACKET Sthrottle body assembly Refer to THROTTLE BODIES in chapter 7 Sair cut off valve Refer to AIR INDUCTION SYSTEM in chapter 7 Sradiator Srad...

Page 86: ...ion stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 3 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at...

Page 87: ...lve pad from falling into the crankcase SMake a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table Valve pad thickness range Available valve pads Nos 120 X 240 1 20 0 0472 X 2 40 mm 0 0945 in 25 thicknesses in 0 05 mm 0 002 in increments SThe thickness a of each valve pad is marked i...

Page 88: ...sect is the new valve pad number The new valve pad number is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lift er 2 SLubricate the valve pad with molybdenum dis ulfide grease SLubricate the valve lifter with molybdenum dis ulfide oil SInstall the valve lifte...

Page 89: ... SFirst install the exhaust camshaft SAlign the camshaft marks with the camshaft cap marks STurn the crankshaft counterclockwise several full turns to seat the parts g Measure the valve clearance again h If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained ...

Page 90: ... 215 220 225 230 235 240 0 96 X 1 00 200 205 210 215 220 225 230 235 240 1 01 X 1 05 205 210 215 220 225 230 235 240 1 06 X 1 10 210 215 220 225 230 235 240 1 11 X 1 15 215 220 225 230 235 240 1 16 X 1 20 220 225 230 235 240 1 21 X 1 25 225 230 235 240 1 26 X 1 30 230 235 240 1 31 X 1 35 235 240 1 36 X 1 40 240 EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215...

Page 91: ...hould be checked 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand 2 Remove Sseat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE 3 Install Svacuum gauge 1 onto the synchronizing hose 2 Vacuum gauge 90890 03094 YU 08030 4 Install Sair filter case Refer to AIR FILTER CA...

Page 92: ...g the air screws 1 1 2 2 3 3 4 4 5 SAfter each step rev the engine two or three times each time for less than a second and check the synchronization again SIf the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization Vacuum pressure at engine idling speed 29 kPa 218 mm...

Page 93: ...let it warm up for several minutes 2 Check Sengine idling speed Out of specification Adjust Engine idling speed 1250 X 1350 r min 3 Adjust Sengine idling speed a Turn the idle adjusting screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is increased Direction Engine idling speed is decreased 4 Adjust Sthrottle cable free play Refer to ADJU...

Page 94: ...ight Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE Sbattery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 3 Adjust Sthrottle cable free play When the throttle is opened the accelerator cable 1 is pulled Throttle body a Loosen the locknut 2 on the decelerator cable b Turn the adjusting nut 3 in direction a or b to take up any slack on the decele...

Page 95: ...Sfront cowling inner panel left and right Refer to COWLINGS Sseat Refer to SEAT After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the carbon monoxide density to standard and then adjust the exhaust gas 1 Turn the main s...

Page 96: ...linder appears on the odo meter LCD RESET button decrement SELECT button increment 6 Execute the selection of the cylinder by si multaneously pressing the SELECT and RESET buttons for approximately 2 se conds 7 After selecting the adjustment cylinder change the Co adjustment volume by pressing the SELECT and RESET but tons SThe Co adjustment volume appears on the odo meter LCD RESET button decreme...

Page 97: ...way any dirt accumulated in the spark plug wells with compressed air to prevent it from fal ling into the cylinders 3 Check Sspark plug type Incorrect Change Spark plug type manufacturer CR9EK NGK 4 Check Selectrode 1 Damage wear Replace the spark plug Sinsulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Sspark plug with a spark plug cleaner or wire brush ...

Page 98: ...n pressure will result in a loss of performance 1 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Srider seat Refer to SEAT Sfront cowling inner panel letf and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE Sbattery Refer to ...

Page 99: ...Minimum 1 350 kPa 13 50 kg cm2 13 50 bar 191 87 psi Standard 1 550 kPa 15 50 kg cm2 15 50 bar 220 46 psi Maximum 1 736 kPa 17 36 kg cm2 17 36 bar 246 92 psi a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug leads before cranking the engine The difference in compression pressure...

Page 100: ...hout oil Piston ring s wear or damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly defective Repair 7 Install Sspark plug 8 Install Sspark plug caps Signition coils 9 Install Sheat protector plate Sbattery box bracket Sbattery box Refer to BATTERY BOX AND BATTERY BOX BRACKET Sbattery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Sair filter case Refer ...

Page 101: ...ximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade ACEA standard G4 or G5 SEngine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any...

Page 102: ...n turn it off 5 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled EAS00074 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 Sengine oil filler cap 1 Sengine oil drain bolt 2 along with the gasket 4 Drain Sengine oil completely ...

Page 103: ...ng 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Oil filter cartridge 17 Nm 1 7 mSkg 12 ftSlb 6 Replace Sengine oil drain bolt gasket New 7 Install Sengine oil drain bolt along with the new gasket 8 Fill Scrankcase with the specified amount of the recom mended engine oil Quantity Total amount ...

Page 104: ...gine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off 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 Soil gallery bolt 1 The engine ...

Page 105: ...ressure as its own data may fluctuate depending on the oil temperature and viscosity the oil pressure may fluctuate when measuring The following data should be used only as a reference when measuring the engine oil pressure Engine oil pressure Possible causes Below ifi i Faulty oil pump specification Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil ...

Page 106: ...able free play is increased Direction Clutch cable free play is decreased If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side 3 Remove Sseat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE a Loosen the lockn...

Page 107: ...el left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK 2 Remove Sair filter case cover 1 Sair filter element 2 3 Clean Sair filter element 2 4 Check Sair filter element Damage Replace 5 Install Sair filter element 2 Sair filter case cover 1 Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Op...

Page 108: ...all Sfuel tank Refer to FUEL TANK Sfront cowling inner panel left and right Refer to COWLINGS Srider seat Refer to SEAT EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Sthrottle bodies Refer to THROTTLE BODIES in chapter 7 2 Check Sthrottle body joints 1 Cracks damage Replace 3 Install Sthrottle bodies Refe...

Page 109: ...erly SBefore removing the fuel hose place a few rags in the area under where it will be re moved SThere is a white mark on the fuel tank breather hose Refer to CABLE ROUTING in chapter 2 3 Install Sfuel tank Refer to FUEL TANK Sfront cowling inner panel left and right Refer to COWLINGS Srider seat Refer to SEAT EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Srider seat Refer to SEAT Sfront...

Page 110: ...move Sradiator Refer to RADIATOR in chapter 6 2 Check Sexhaust pipe 1 Scatalyst pipe 2 Smuffler 3 Cracks damage Replace Sgasket 4 Exhaust gas leaks Replace 3 Check Stightening torque Exhaust pipe nut 5 20 Nm 2 0 mSkg 15 ftSlb Catalyst joint bolt 6 20 Nm 2 0 mSkg 15 ftSlb Muffler joint bolt 7 Muffler and muffler stay 8 20 Nm 2 0 mSkg 15 ftSlb Exhaust pipe and exhaust pipe stay 9 20 Nm 2 0 mSkg 15 f...

Page 111: ...Below the minimum level mark Add the recommended coolant to the proper level SAdding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant SUse only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for seve...

Page 112: ...ooler inlet hose 5 Soil cooler outlet hose 6 Swater jacket outlet joint 7 Swater jacket hose 8 Swater pump outlet pipe 9 Swater pump outlet hose 10 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 EAS00105 CHANGING THE COOLANT 1 Remove Sseat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK 2 Remove Scoolant reservoir tank ...

Page 113: ...the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his sing sound has stopped press down on the radiator cap and turn it counterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 6 Remove Scoolant dr...

Page 114: ...nt reservoir capacity 0 27 L 0 24 Imp qt 0 29 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care SIf coolant splashes in your eyes thorough ly wash them with water and consult a doc tor SIf coolant splashes on your clothes quick ly wash it away with water and then with soap and water SIf coolant is swallowed induce vomiting and get immediate med...

Page 115: ...l Sradiator cap 14 Fill Scoolant reservoir tank with the recommended coolant to the maxi mum level mark a 15 Install Scoolant reservoir cap 16 Start the engine warm it up for several min utes and then stop it 17 Check Scoolant level Refer to CHECKING THE COOLANT LEV EL Before checking the coolant level wait a few minutes until the coolant has settled 18 Install Sfuel tank Refer to FUEL TANK Sfront...

Page 116: ...ion 1 Distance is the largest Position 5 Distance is the smallest SAfter adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjust ing dial SA soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the b...

Page 117: ... pedal is raised Direction Brake pedal is lowered After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification Locknut 18 Nm 1 8 mSkg 13 ftSlb A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding...

Page 118: ...d the recommended brake fluid to the proper level Recommended brake fluid DOT 4 A Front brake B Rear brake SUse only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill 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 br...

Page 119: ... to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS00118 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Sfront brake pad Srear brake pad Brake pad wear limit a b Wear limit reached Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 4...

Page 120: ...body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction Brake light comes on later EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Sbrake hose Cracks ...

Page 121: ...ngthening the bleeding procedure SIf bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Shydraulic brake system a Fill the brake fluid reservoir to the proper lev el with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hos...

Page 122: ...eservoir to the proper lev el with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake operation EAS00136 ADJUSTING THE SHIFT PEDAL 1 Check Sshift pedal position Align the center of shift pedal 1 and center of footrest bracket bolt 2 in a straight line Incorrect Adjust 2 Adjust Sshift pedal position a Loosen both locknuts 2 ...

Page 123: ...face Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of drive chain 3 Check Sdrive chain slack a Out of specification Adjust Drive chain slack 45 X 55 mm 1 77 X 2 17 in 4 Adjust Sdrive chain slack a Loosen the wheel axle nut 1 ...

Page 124: ...e serviced especially when the motorcycle is used in dusty areas This motorcycle has a drive chain with small rubber O rings between each side plate Steam cleaning high pressure washing certain sol vents and the use of a coarse brush can dam age these O rings Therefore use only kerosine to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant...

Page 125: ...p the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Supper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4 4 Adjust Ssteering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5 Set the torque wrench at...

Page 126: ...ghten the upper ring nut 8 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 9 Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Supper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4 6 Measure Ssteering head tension Make sure all of the cables a...

Page 127: ...bove procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head EAS00149 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check Sinner tube 1 Damage scratches Replace Soil seal 2 ...

Page 128: ...e maximum or minimum adjustment positions 1 Adjust Sspring preload a Adjust the spring preload with a ring nut wrench Ring nut wrench 90890 01268 YU 01268 b Turn the adjusting ring 1 in direction a or b c Align the desired position on the adjusting ring with the stopper 2 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting...

Page 129: ...rloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 207 kg 456 lb Maximum load 190 kg 419 lb Cold tire pressure Front Rear Up to 90 kg 198 lb load 225 kPa 2 25 kgf cm2 2 25 bar 33psi 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 90 kg X 190 kg 198 X 419 lb maximum load 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 290 kPa 2 9 k...

Page 130: ...sure the wheel rim band and tube are centered in the wheel groove SPatching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement A Tire B Wheel Tube wheel Tube tire only T beless wheel Tube or tubeless Tubeless wheel tire SAfter extensive tests the tires listed below have been approved b...

Page 131: ...e until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed be fore any high speed riding is done For tires with a direction of rotation mark 1 SInstall the tire with the mark pointing in the direction of wheel rotation SAlign the mark 2 with the valve installation point EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 ...

Page 132: ...bricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease EAS00172 LUBRICATING THE SIDEST...

Page 133: ...ICATING THE REAR SUSPENSION CHK ADJ EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfide grease ...

Page 134: ...electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL SSkin Wash with water SEyes Flush with water for 15 minutes and get immediate medical attention INTERNAL SDrink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion SThis is a sealed battery Never remove the sealing ...

Page 135: ...ider seat Refer to SEAT Sfront cowling inner panel left and right Refer to COWLINGS Sfuel tank Refer to FUEL TANK 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Positive tester probe positive battery terminal Negativ...

Page 136: ...ve bat tery lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure the battery charger lead clips are in full contact with the battery terminal and that they are not shor...

Page 137: ...n checking steps If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the battery unused fo...

Page 138: ...rging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Set the charging time at 20 hours maximum YES NO NOTE Voltage should be ...

Page 139: ...ery leads to the battery terminals First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Sbattery terminals Dirt Clean with a wire brush Loose con nection Connect properly 9 Lubricate Sbattery terminals Recommended lubricant Dielectric grease 10 Install Sfuel tank Refer to FUEL TANK Sfront cowling inner panel left and right Refer to COWLINGS Sseat Refer to SEAT ...

Page 140: ... the pocket tester selector to Ω 1 Pocket tester 90890 03112 YU 3112 b If the pocket tester indicates replace the fuse 3 Replace Sblown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Fuses Amperage rating Q ty Main 30A 1 ...

Page 141: ...ating 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 the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Sright side cover Refer to COWLINGS ...

Page 142: ...ts and your hands away from the bulb until it has cooled down 5 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with...

Page 143: ... adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left headlight Direction Headlight beam moves to the right Direction Headlight beam moves to the left Right headlight Direction Headlight beam moves to the left Direction Headlight beam moves to the right...

Page 144: ......

Page 145: ...RAKES 4 16 FRONT BRAKE PADS 4 16 REAR BRAKE PADS 4 17 REPLACING THE FRONT BRAKE PADS 4 19 REPLACING THE REAR BRAKE PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE MASTER CYLINDER 4 26 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 28 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 29 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLI...

Page 146: ...NDER BRACKET 4 59 REMOVING THE UNDER BRACKET 4 61 CHECKING THE STEERING HEAD 4 61 INSTALLING THE STEERING HEAD 4 62 REAR SHOCK ABSORBER ASSEMBLY 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 HANDLING THE REAR SHOCK ABSORBER 4 66 DISPOSING OF A REAR SHOCK ABSORBER 4 66 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 66 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 67 SWINGARM AND DRIVE CHAIN 4 68...

Page 147: ...right Front wheel Front brake disc left and right 2 2 1 1 2 1 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen For installation reverse the removal procedure NOTE 40 Nm 4 0 mSkg 29 ftSlb 18 Nm 1 8 mSkg 13 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 72 Nm 7 2 mSkg 52 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 6 Nm 0 6 mSkg 4 3 ...

Page 148: ... CHAS Order Job Part Q ty Remarks Disassembling the front wheel Oil seal left and right Wheel bearing left and right Spacer 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 EAS00518 ...

Page 149: ... the front wheel is elevated 2 Remove Sleft brake caliper Sright brake caliper Do not apply the brake lever when removing the brake calipers 3 Elevate Sfront wheel Place the motorcycle on a suitable stand so that the front wheel is elevated 4 Loosen Sfront wheel axle pinch bolt 5 Remove Sfront wheel axle Sfront wheel EAS00525 CHECKING THE FRONT WHEEL 1 Check Swheel axle Roll the wheel axle on a fl...

Page 150: ...eplace Radial wheel runout limit 1 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in 4 Check Swheel bearings Front wheel turns roughly or is loose Re place the wheel bearings Soil seals Damage wear Replace 5 Replace Swheel bearings New Soil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 betwe...

Page 151: ...o all of the brake discs 1 Check Sbrake disc Damage galling Replace 2 Measure Sbrake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit maximum Front 0 1 mm 0 004 in Rear 0 15 mm 0 006 in a Place the motorcycle on a suitable stand so that the wheel is elevated b Before measuring the front brake disc deflec tion turn the hand...

Page 152: ...hten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 18 Nm 1 8 mSkg 13 ftSlb LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EAS00545 INSTALLING THE FRONT WHEEL The following...

Page 153: ...rd in the handlebar several times and check if the front fork rebounds smoothly 6 Install Sbrake calipers left and right Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs 7 Install Sbrake hose holder Make sure the brake hose is routed properly EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE SAfter replacing the tire wheel or bo...

Page 154: ... all the marks come to rest is the front wheel s heavy spot X 3 Adjust Sfront wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X Start with the lightest weight b Turn the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wh...

Page 155: ...heel axle Washer Drive chain puller left and right Rear wheel Rear brake caliper bracket 1 2 2 1 1 1 1 2 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen For installation reverse the removal procedure NOTE 27 Nm 2 7 mSkg 20 ftSlb 22 Nm 2 2 mSkg 16 ftSlb 120 Nm 12 mSkg 87 ftSlb EAS00551 REAR WHEEL AND BRAKE DISC REAR ...

Page 156: ...sprocket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel 1 1 2 2 2 1 6 1 Remove the parts in the order listed For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 100 Nm 10 mSkg 72 ftSlb EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 157: ... CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Collar Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 3 2 4 5 6 EAS00560 ...

Page 158: ...torcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sbrake caliper 1 Do not depress the brake pedal when removing the brake caliper 3 Loosen Slocknut 1 Sadjusting nut 2 4 Remove Swheel axle nut 3 Swheel axle 4 Swasher Srear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Sleft collar 1 Srear wheel drive hub 2 Srear wheel drive...

Page 159: ... Measure Sradial wheel runout Slateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Srear wheel drive hub 1 Cracks damage Replace Srear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Srear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace th...

Page 160: ...wheel sprocket self locking nut 100 Nm 10 mSkg 72 ftSlb Tighten the self locking nuts in stages and in a crisscross pattern EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate Swheel axle Swheel bearings Soil seal lips Recommended lubricant Lithium soap based grease 2 Install Scollars Srear brake caliper bracket Srear wheel Swasher Srear wheel axle 3 Adjust Sdrive chain slack Drive drain slack 45 X 55 ...

Page 161: ...TIC BALANCE SAfter replacing the tire wheel or both the rear wheel static balance should be adjusted SAdjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Srear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE ...

Page 162: ...ake pad Brake pad spring Bleed screw 1 2 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers For installation reverse the removal procedure NOTE 10 Nm 1 0 mSkg 7 2 ftSlb 40 Nm 4 0 mSkg 29 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 163: ...ake pad pin Rear brake caliper Brake pad shim Brake pad Brake screw Brake pad spring 1 1 1 4 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure 3 Nm 0 3 mSkg 2 2 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb 27 Nm 2 7 mSkg 20 ftSlb 22 Nm 2 2 mSkg 16 ftSlb REAR BRAKE PADS ...

Page 164: ...must be disassembled drained cleaned properly filled and bled after reas sembly SNever use solvents on internal brake com ponents SUse only clean or new brake fluid for clean ing brake components SBrake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately SAvoid brake fluid coming into contact with the eyes as it can cause serious injury F...

Page 165: ...e caliper 1 Remove Sbrake hose holder 1 Sbrake caliper 2 2 Remove Sbrake pads 1 along with the brake pad shims Sbrake pad shims onto the brake pads Sbrake pad spring 3 Measure Sbrake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 0 8 mm 0 03 in 4 Install Sbrake pad spring Sbrake pad shims onto the brake pads Sbrake pads Always install new brake pads brak...

Page 166: ...with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 mSkg 4 3 ftSlb d Install a new brake pad shim onto each new brake pad 5 Install Sbrake caliper 6 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check Sbrake lever operation Soft or spongy feeling Bleed the brake system R...

Page 167: ... pad spring 4 2 Remove Sbrake pads 1 along with the brake pad shims 3 Measure Sbrake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 1 0 mm 0 04 in 4 Install Sbrake pad spring Sbrake pad shims onto the brake pads Sbrake pads Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed ...

Page 168: ...rew 6 Nm 0 6 mSkg 4 3 ftSlb d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Sbrake pad cover Sbrake caliper front rear Sbrake pad pin Sscrew plug 6 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check Sbrake pedal operation Soft or spongy feeling Bleed the brake ...

Page 169: ...holder Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead coupler Front brake light switch Union bolt Copper washer Master cylinder holder 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Disconnect 2 Nm 0 2 mSkg 1 4 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 10 Nm 1 0 mSkg 72 ftSlb EAS00584 FRONT BRAKE MASTE...

Page 170: ...4 FRONT AND REAR BRAKES CHAS Order Job Part Q ty Remarks 10 Master cylinder assembly 1 For installation reverse the removal procedure 2 Nm 0 2 mSkg 1 4 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 10 Nm 1 0 mSkg 72 ftSlb ...

Page 171: ... ty Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 EAS00585 ...

Page 172: ...Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt Copper washer Brake hose Master cylinder assembly 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 23 Nm 2 3 mSkg 17 ftSlb EAS00586 REAR BRAKE MASTER CYLINDE...

Page 173: ...art Q ty Remarks Disassembling the rear brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 EAS00587 ...

Page 174: ...nder the master cylinder and the end of the brake hose 3 Remove Sbrake lever Smaster cylinder bracket Smaster cylinder assembly 4 Remove Scirclip from the master cylinder assembly Smaster cylinder kit EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders 1 Check Sbrake master cylinder 1 Damage scratches wear Replace Sb...

Page 175: ...es Cracks damage wear Replace Refer to CHECKING THE FRONT AND REAR BRAKE HOSES in chapter 3 EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove Sunion bolt 1 Scopper washers 2 Sbrake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Disconnect Sbrake fluid reservoir hose 3 Remove Spin from the brake pedal link 4 Remov...

Page 176: ...der kit Scirclip New Sbrake master cylinder 1 SInstall the brake master cylinder holder with the UP mark facing up SAlign the end of the brake master cylinder holder with the punch mark a on the handle bar SFirst tighten the upper bolt then the lower bolt 2 Install Scopper washers 1 New Sbrake hose 2 Sunion bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to...

Page 177: ...he system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid i...

Page 178: ...ure the brake pipe touches the projection a as shown 3 Fill Sbrake fluid reservoir to the maximum level mark a Recommended brake fluid DOT 4 SUse only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful ch...

Page 179: ...chapter 3 5 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust Sbrake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest 25 8 mm 1 02 in 7 Adjust Srear brake light operation timing Refer to ADJUSTING THE REAR BR...

Page 180: ...Brake caliper bracket 1 2 1 1 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal procedure NOTE 10 Nm 1 0 mSkg 72 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 40 Nm 4 0 mSkg 29 ftSlb 40 Nm 4 0 mSkg 29 ftSlb EAS00613 FRONT BRAKE CALIPERS ...

Page 181: ...Brake pad Brake caliper piston Brake caliper piston seal Brake pad spring Bleed screw 2 2 4 1 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers For assembly reverse the disassembly procedure NOTE 1 2 3 4 5 6 Nm 0 6 mSkg 4 3 ftSlb EAS00615 ...

Page 182: ...uid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal procedure 22 Nm 2 2 mSkg 16 ftSlb 27 Nm 2 7 mSkg 20 ftSlb 30 Nm 3 0 mSkg 22 ftSlb EAS00616 REAR BRAKE CALIPER ...

Page 183: ...ke pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw 1 1 2 4 1 1 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 6 Nm 0 6 mSkg 4 3 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 3 Nm 0 3 mSkg 2 2 ftSlb EAS00617 ...

Page 184: ...e hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper SCover the brake caliper piston with a rag Be careful not the get injured when the pis ...

Page 185: ...he end of the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper piston 1 Sbrake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper SCover the brake caliper piston with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper SNever try to pry out t...

Page 186: ...sembled 1 Check Sbrake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Sbrake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Sbrake caliper body 3 Cracks damage Replace the brake cali per assembly Sbrake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake calip...

Page 187: ...Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper bracket Sbrake pads Sbrake caliper 1 Scopper washers New Sbrake hose 2 Sunion bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operati...

Page 188: ...ce SWhen refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check Sbrak...

Page 189: ...o swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper 1 front rear Sbrake pad pin Sscrew plug Scopper washers New Sbrake hose 2 Sunion bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 m...

Page 190: ...e brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake...

Page 191: ... bracket pinch bolt Under bracket pinch bolt Front fork leg 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT AND REAR BRAKES Loosen Loosen Loosen For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb 30 Nm 3 0 mSkg 22 ftSlb EAS00647 FRONT FORK FRONT FORK LEGS ...

Page 192: ...pring Dust seal Oil seal clip Damper rod assembly bolt Copper washer Damper rod assembly Oil seal Washer 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The following the procedure applies to both of the front fork legs NOTE 1 3 2 4 5 6 7 8 9 10 11 12 24 Nm 2 4 mSkg 17 ftSlb 23 Nm 2 3 mSkg 17 ftSlb EAS00648 ...

Page 193: ...rder Job Part Q ty Remarks Inner tube Outer tube bushing Inner tube bushing Oil flow stopper Outer tube 1 1 1 1 1 For assembly reverse the disassembly procedure 13 14 15 16 17 24 Nm 2 4 mSkg 17 ftSlb 23 Nm 2 3 mSkg 17 ftSlb ...

Page 194: ...cle on a suitable stand so that the front wheel is elevated 2 Loosen Supper bracket pinch bolt 1 Scap bolt 2 Sunder bracket pinch bolt 3 Before loosening the upper and under bracket pinch bolts support the front fork leg 3 Remove Sfront fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Scap bolt Swasher Sspacer Sfork spring ...

Page 195: ...amper rod holder 90890 01294 T handle 90890 01326 5 Remove Sinner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully SExcessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced SAvoid bottoming the i...

Page 196: ...fication Replace Spring free length 354 mm 13 94 in Limit 347 mm 13 66 in 3 Check Sdamper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Soil flow stopper 2 Damage Replace SThe front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material SWhen disassembling and a...

Page 197: ...t seal before assembling the front fork leg make sure all of the components are clean 1 Install Sinner tube busing Souter tube busing Soil flow stopper Sdamper rod assembly 1 Scopper washer New Always use new copper washer Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Sinner...

Page 198: ...l 1 with the fork seal driver weight and fork seal driver attachment Make sure the numbered side of the oil seal faces up SBefore installing the oil seal lubricate its lips with lithium soap based grease SLubricate the outer surface of the inner tube with fork oil SBefore installing the oil seal cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation 6 ...

Page 199: ...ecommended fork oil Other oils may have an adverse effect on front fork performance SWhen disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 Measure Sfront fork leg oil level a Out of specification Correct Front fork leg oil level from the top of the inner tube with the inner tube fully compressed and without the fork spring 134 mm 5 28 in ...

Page 200: ...e cap bolt lubricate its O ring with grease b Larger pitch EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Sfront fork leg Temporarily tighten the upper and under bracket pinch bolts Make sure the inner fork tube is flush with the top of the upper bracket 2 Tighten Sunder bracket pinch bolt 1 Scap bolt 2 Supper bracket pinch bolt 3 M...

Page 201: ...ar switch Throttle grip Throttle cable Front brake light switch connector Front brake master cylinder holder Front brake master cylinder Upper handlebar holder Handlebar 2 1 1 1 1 1 1 1 2 1 1 1 2 1 Remove the parts in the order listed Disconnect Disconnect For installation reverse the removal procedure 23 Nm 2 3 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 26 Nm 2 6 mSkg 19 ftSlb 11 Nm 1 1 mSkg 8 0 ftSl...

Page 202: ...ar grip and gradually push the grip off the handlebar 3 Disconnect Sclutch switch connector 4 Remove Sleft handlebar switch 1 Sclutch cable 2 Sclutch lever holder 3 5 Remove Sgrip end Sfront brake light switch connector Sright handlebar switch 1 Sthrottle grip 2 Sfront brake master cylinder holder 3 Sfront brake master cylinder EAS00668 CHECKING THE HANDLEBAR 1 Check Shandlebar 1 Bends cracks dama...

Page 203: ... with the fuel tank adjust the handlebar position Align the match marks a on the handlebar with the upper surface of the lower handlebar hold ers 3 Install Sthrottle cables Sright handlebar switch 1 Sthrottle grip 2 Align the projections a on the handlebar switch with the holes b in the handlebar 4 Install Sfront brake master cylinder 1 Sfront brake master cylinder holder 2 Refer to ASSEMBLING AND...

Page 204: ...the handlebar 8 Adjust Sclutch cable free play Refer to ADJUST THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 X 15 mm 0 39 X 0 59 in 9 Install Sleft handlebar switch Align the projection a on the left handlebar switch with the hole b on the handlebar 10 Install Shandlebar grip Sgrip end a Apply a thin coat of rubber adhesive onto the left end of th...

Page 205: ...upler Immobilizer coupler Steering stem nut Washer Upper bracket Horn stay Lock washer 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to HANDLEBAR Refer to COWLINGS in chapter3 Refer to FUEL TANK in chapter 3 Disconnect Disconnect Refer to FRONT FORK 30 Nm 3 0 mSkg 22 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 110 Nm 11 mSkg 80 ftSlb EAS00676 STEERING HEAD UNDER B...

Page 206: ...per ring nut Rubber washer Lower ring nut Under bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race 1 1 1 1 1 2 1 1 1 2 For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 110 Nm 11 mSkg 80 ftSlb ...

Page 207: ... washer Sring nut 1 with the steering nut wrench 2 Hold the lower ring nut with the exhaust and steering nut wrench and then remove the upper rung nut with the ring nut wrench Steering nut wrench 90890 01403 YU 33975 Securely support the under bracket so that there is no danger of it falling over EAS00682 CHECKING THE STEERING HEAD 1 Wash Sbearing balls Sbearing races Recommended cleaning solvent ...

Page 208: ...erly the steering head pipe could be damaged SAlways replace the bearing balls and bearing races as a set SWhenever the steering head is disassembled replace the dust seal 4 Check Supper bracket Slower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate Supper bearing Slower bearing Sbearing races Recommended lubricant Lithium soap bas...

Page 209: ...4 63 STEERING HEAD CHAS 110 Nm 11 mSkg 80 ftSlb 3 Install Supper bracket Swasher Ssteering stem nut 4 Install Sfront fork legs Refer to INSTALLING THE FRONT FORK LEGS ...

Page 210: ...ar bolt Swingarm rear shock absorber Self locking nut washer bolt Frame rear shock absorber Rear shock absorber Oil seal bearing 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to REAR WHEEL AND BRAKE DISC For installation reverse the removal procedure 40 Nm 4 0 mSkg 29 ftSlb 40 Nm 4 0 mSkg 29 ftSlb EAS00685 REAR SHOCK ABSORBER ASSEMBLY ...

Page 211: ...o danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Srear wheel Refer to REAR WHEEL AND BRAKE DISC 3 Remove Srear shock absorber assembly lower bolt 1 While removing the rear shock absorber as sembly lower bolt hold the swingarm so that it does not drop down 4 Remove Srear shock absorber assembly upper bolt 1 Srear shock absorber assembl...

Page 212: ...rce of high heat High heat can cause an explosion due to excessive gas pressure SDo not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping perfor mance EAS00688 DISPOSING OF A REAR SHOCK ABSORBER Gas pressure must be released before dispos ing of a rear shock absorber To release the gas pressure drill a 2 X 3 mm hole through the rear shock ab...

Page 213: ... ASSEMBLY 1 Lubricate Scollar Sbearings Soil seals Recommended lubricant Lithium soap based grease 2 Install Scollar Srear shock absorber assembly When installing the rear shock absorber assem bly lift up the swingarm 3 Tighten Srear shock absorber assembly upper nut 1 Srear shock absorber assembly lower nut 2 4 Install Srear wheel Refer to REAR WHEEL AND BRAKE DISC 5 Adjust Sdrive chain slack Ref...

Page 214: ... Adjusting nut Rear fender Pivot shaft nut washer Pivot shaft Swingarm Drive chain 2 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL AND BRAKE DISC Refer to REAR SHOCK ABSORBER ASSEMBLY Refer to ENGINE in chapter 5 Loosen Loosen Refer to EXHAUST PIPE in chapter 5 120 Nm 12 mSkg 87 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 16 Nm 1 6 mSkg 12 ftSlb SWINGARM AND DRIVE CHAIN CHAS SWINGARM AN...

Page 215: ...VE CHAIN CHAS Order Job Part Q ty Remarks 8 9 10 11 Drive chain guide Dust cover Bearing Spacer 1 2 2 1 For installation reverse the removal procedure 120 Nm 12 mSkg 87 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 16 Nm 1 6 mSkg 12 ftSlb ...

Page 216: ... AS SEMBLY 3 Measure Sswingarm side play Sswingarm vertical movement a Measure the tightening torque of the pivot shaft nut Pivot shaft nut 120 Nm 12 mSkg 87 ftSlb b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0 mm 0 ...

Page 217: ... the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sdrive chain with the drive chain cutter EAS00707 CHECKING THE SWINGARM 1 Check Sswingarm Bends cracks damage Replace 2 Check Spivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash Spivot shaft Sdust covers Sspacer Swashers Sbearings Recommended cleaning...

Page 218: ...earings Sspacer Sdust covers Spivot shaft Recommended lubricant Lithium soap based grease 2 Install Sswingarm 1 Spivot shaft nut 2 3 Install Srear shock absorber assembly Srear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and INSTAL LING THE REAR WHEEL 4 Adjust Sdrive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 45 X 55 mm 1 77 X 2 17 in ...

Page 219: ...Stiffness Clean and lubricate or replace 3 Clean Sdrive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain solvents ...

Page 220: ...nd make sure that the battery breather hose is proper ly routed away from the drive chain and be low the swingarm 5 Lubricate Sdrive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 6 Check Sdrive sprocket Srear wheel sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprock ets as a set b Correct 1 ...

Page 221: ......

Page 222: ...THE CYLINDER HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 30 STARTER CLUTCH AND GENERATOR 5 32 STATOR COIL ASSEMBLY 5 32 REMOVING THE GENERATOR 5 34 REMOVING THE STARTER CLUTCH 5 35 CHEC...

Page 223: ...CHECKING THE RELIEF VALVE 5 59 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5 59 CHECKING THE OIL STRAINER 5 59 CHECKING THE OIL NOZZLES 5 59 ASSEMBLING THE OIL PUMP 5 60 INSTALLING THE OIL PUMP 5 60 INSTALLING THE OIL STRAINER 5 61 INSTALLING THE OIL PAN 5 61 CRANKCASE 5 62 DISASSEMBLING THE CRANKCASE 5 64 CHECKING THE CRANKCASE 5 65 CHECKING THE BEARINGS AND OIL SEALS 5 65 CHECKING THE TIMING CHA...

Page 224: ...L BEARINGS 5 80 INSTALLING THE CRANKSHAFT 5 83 TRANSMISSION 5 84 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 84 REMOVING THE TRANSMISSION 5 90 CHECKING THE SHIFT FORKS 5 90 CHECKING THE SHIFT DRUM ASSEMBLY 5 91 CHECKING THE TRANSMISSION 5 91 INSTALLING THE TRANSMISSION 5 92 ...

Page 225: ...ENG ...

Page 226: ...ver Nut Lock washer Drive sprocket 2 1 1 1 1 1 1 Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Loosen For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 90 Nm 9 0 mSkg 65 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb ENGINE ENG EAS00188 ENGINE ENGINE DRIVE SPROCKET ...

Page 227: ...mbly Muffler 1 4 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 20 Nm 2 0 mSkg 15 ftSlb 16 Nm 1 6 mSkg 11 6 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 9 Nm 0 9 mSkg 6 5 ftSlb 34 Nm 3 4 mSkg 26 ftSlb ENGINE ENG EAS00189 EXHAUST PIPE ...

Page 228: ...ct the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to BATTERY BOX AND BATTERY BOX BRACKET in chapter 3 Refer to THROTTLE BODIES in chapter 7 Refer to OIL COOLER in chapter 6 Refer to AIR INDUCTION SYSTEM in chapter 7 Drain Refer...

Page 229: ...d Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler 1 1 1 1 1 1 1 1 1 Refer to COOLING SYSTEM in chapter 6 Refer to STARTER MOTOR in chapter 8 Disconnect Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure ENGINE ENG ...

Page 230: ... nut Rear engine mounting bolt Engine 1 2 2 2 1 Remove the parts in the order listed Place a suitable stand under the frame and engine For installation reverse the removal procedure NOTE Refer to INSTALLING THE ENGINE 55 Nm 5 5 mSkg 40 ftSlb 55 Nm 5 5 mSkg 40 ftSlb 55 Nm 5 5 mSkg 40 ftSlb 55 Nm 5 5 mSkg 40 ftSlb ENGINE ENG EAS00191 ENGINE ...

Page 231: ...ine mounting bolts 1 Lubricate the rear engine mounting bolt threads with lithium soap based grease 2 Install Sright front engine mounting bolt 2 Sleft front engine mounting bolts 3 Do not fully tighten the bolts 3 Tighten Sself locking nut 4 First tighten the lower self locking nut 4 Tighten Sleft front engine mounting bolts 5 ...

Page 232: ...Skg 7 2 ftSlb NOTE 5 Tighten Sright front engine mounting bolts 6 6 Install Sshift arm 7 SAlign the punch mark a in the shift shaft with the slot in the shift arm SAlign the bottom edge of the shift pedal with the mark on the frame to swingarm bracket ...

Page 233: ...guide top side 4 4 1 1 1 Remove the parts in the order listed Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to BATTERY BOX AND BATTERY BOX BRACKET in chapter 3 Refer to THROTTLE BODIES in chapter 7 Refer to COOLING SYSTEM in chapter 6 Refer to AIR INDUCTION SYSTEM in chapter 7 For installation reverse the removal procedure 18 Nm 1 8 mSkg 13 ftS...

Page 234: ...aft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft 4 1 1 1 3 6 3 6 1 Remove the parts in the order listed Refer to CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR Loosen During removal the dowel pins may still be connected to the camshaft caps NOTE 10 Nm 1 0 mSkg 7 2 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CAMSHAFTS ENG EAS0...

Page 235: ...11 12 13 Exhaust camshaft Pin Timing chain guide intake side Cam sprocket 1 1 1 2 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 20 Nm 2 0 mSkg 15 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 236: ...align the T mark a on the pick up rotor with the crankcase mating surface b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Scamshaft sprocket bolts 1 4 Loosen Scap bolt 2 5 Remove Stiming chain tensioner 3 Sgasket 6 Remove Stiming chain guide exhaust side Scamshaft caps 4 Sdowel pins To prevent damage to the cylinder head camshafts or ca...

Page 237: ... discoloration pitting scratches Re place the camshaft 2 Measure Scamshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 32 45 X 32 55 mm 1 278 X 1 282 in Limit 32 40 mm 1 276 in b 24 95 mm X 25 05 mm 0 982 X 0 986 in Limit 24 90 mm 0 980 in Exhaust camshaft a 32 45 X 32 55 mm 1 278 X 1 282 in Limit 32 40 mm 1 276 in b 24 95 X 25...

Page 238: ...Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps STighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out SDo not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Camshaft cap bolt 10 Nm 1 0 mSkg 7 2 ftSlb d Remove the camshaft caps and then mea sure the width...

Page 239: ...t a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check Stiming chain guide exhaust side 1 Stiming chain guide intake side 2 Stiming chain guide top side 3 Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check Stiming chain tensioner Cracks damage Replace 2 Check Sone way cam operation Rough movement Replace the timing chain tensioner assem...

Page 240: ...Saluminum washer New Sgasket New Damage wear Replace the defective part s EAS00215 INSTALLING THE CAMSHAFTS 1 Align S T mark a on the pickup rotor with the crankcase mating surface b a Turn the crankshaft clockwise b When piston 1 is at TDC align the T mark a with the crankcase mating surface b 2 Install Sexhaust camshaft 1 Sintake camshaft 2 with the camshaft sprocket temporarily tightened Make s...

Page 241: ...s and in a crisscross pattern working from the inner caps out I1 I2 Intake side camshaft cap mark E1 E2 Exhaust side camshaft cap mark SLubricate the camshaft cap bolts with the engine oil SThe camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result SDo not turn the crankshaft when installing the camshaft to avoid damage or improper valve ...

Page 242: ...ain tensioner bolt 12 Nm 1 2 mSkg 8 7 ftSlb d Remove the screwdriver make sure that the timing chain tensioner rod releases and then tighten the cap bolt to the specified torque Cap bolt 7 Nm 0 7 mSkg 5 1 ftSlb 7 Turn Scrankshaft several full turns clockwise 8 Check S T mark a Make sure the T mark on the pickup rotor is aligned with the crankcase mating sure face b Scamshaft sprocket match mark c ...

Page 243: ...5 18 CAMSHAFTS ENG 10 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 ...

Page 244: ...e bracket Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to CAMSHAFTS Refer to ENGINE For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 19 Nm 1 9 mSkg 14 ftSlb 50 Nm 5 0 mSkg 36 ftSlb 1st 2nd CYLINDER HEAD ENG EAS00221 CYLINDER HEAD ...

Page 245: ...k plug bore threads Svalve seats 2 Check Scylinder head Damage scratches Replace Scylinder head water jacket Mineral deposits rust Eliminate 3 Measure Scylinder head warpage Out of specification Resurface the cylin der head Maximum cylinder head warpage 0 05 mm 0 002 in a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurf...

Page 246: ...cavity 3 Tighten Scylinder head bolts 1 X 10 1st 2nd Scylinder head bolts 11 12 SLubricate the cylinder head bolts with engine oil STighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages SFirst tighten the bolts 1 X 10 to approximate ly 19 Nm 1 9 mSkg 14 ftSlb with a torque wrench and then tighten the 50 Nm 5 0 mSkg 36 ftSlb 4 Install Sexhaust cams...

Page 247: ...g seat Intake valve spring outer Intake valve spring inner Intake valve stem seal Intake valve lower spring seat Intake valve Intake valve guide Exhaust valve lifter Exhaust valve pad Exhaust valve cotter 8 8 16 8 8 8 8 8 8 8 8 8 16 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING INSTALLING THE VALVES VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS ...

Page 248: ...s 14 15 16 17 18 19 Exhaust valve upper spring seat Exhaust valve spring Exhaust valve stem seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 8 8 8 8 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE VALVES ...

Page 249: ...e position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check Svalve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 3 Remove Svalve co...

Page 250: ...lly so that it can be reinstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification Replace the valve guide Valve stem to valve guide clearance Intake 0 010...

Page 251: ...stalling the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover 4 mm 0 16 in 90890 04111 Valve guide installer 4 mm 0 16 in 90890 04112 Valve guide reamer 4 mm 0 16 in 90890 04113 YM 04113 3 Eliminate Scarbon deposits from the valve face and valve seat 4 Ch...

Page 252: ... mm 0 0016 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Scarbon deposits from the valve face and valve seat 2 Check Svalve seat Pitting wear Replace the cylinder head 3 Measure Svalve seat width a Out of specification Replace the cylinder head Valve seat width 0 9 X 1 1 mm 0 0354 X 0 0433 in Limit 1 6 mm 0 06 in a Apply Mecha...

Page 253: ...to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedur...

Page 254: ...gth Intake valve spring inner 37 0 mm 1 46 in Limit 35 2 mm 1 39 in Intake valve spring outer 38 4 mm 1 51 in Limit 36 5 mm 1 44 in Exhaust valve spring 41 8 mm 1 65 in Limit 39 7 mm 1 56 in 2 Measure Scompressed valve spring force a Out of specification Replace the valve spring b Installed length Compressed valve spring force installed Intake valve spring inner 69 0 X 79 0 N 7 03 X 8 05 kg 15 50 ...

Page 255: ...lve lifters 1 Check Svalve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Svalve stem end with an oil stone 2 Lubricate Svalve stem 1 Svalve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install Svalve 1 Slower sprin...

Page 256: ...pressor attachment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 YM 01253 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive force could damage the valve 6 Install Svalve pad 1 Svalve lifter 2 SLubricate the valve lifter and valve pad with molybdenum disulfide oil S...

Page 257: ...il assembly lead holder 1 1 1 2 1 Remove the parts in the order listed Refer to SEAT and FUEL TANK in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect 32 Nm 3 2 mSkg 23 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 75 Nm 7 5 mSkg 54 ftSlb Drain Refer to CHANGING THE COOLANT in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb STARTER CLUTCH AND GENERATOR ENG EAS00341 STARTER CLU...

Page 258: ...Washer Generator rotor Starter clutch assembly Idler gear shaft Idler gear Starter clutch drive gear 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE GENERATOR 32 Nm 3 2 mSkg 23 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 75 Nm 7 5 mSkg 54 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb ...

Page 259: ...in chapter 3 Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 3 Remove Sgenerator rotor cover Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 4 Remove Sgenerator rotor bolt 1 Swasher SWhile holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor bolt SDo not allow the sheave hold...

Page 260: ...r set s center bolt and the crank shaft Make sure the flywheel puller is centered over the generator rotor Flywheel puller 90890 01362 YU 33270 Flywheel puller attachment 90890 04089 YM 33282 REMOVING THE STARTER CLUTCH 1 Remove Sstarter clutch bolt 1 SWhile holding the generator rotor with the sheave holder remove the starter clutch bolt SDo not allow the sheave holder to touch the projection on ...

Page 261: ...ter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the start er clutch drive gear should engage other wise the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear counterclockwise B it should turn freely otherwise t...

Page 262: ...ean the tapered portion of the crankshaft and the generator rotor hub SReplace the washer with a new one 2 Tighten Sgenerator rotor bolt 1 SWhile holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt SDo not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 YS 01880 A 3 Apply Ssealant onto the stator coil assembly lea...

Page 263: ...in a crisscross pattern 6 Fill Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 Scoolant Refer to CHANGING THE COOLANT in chapter 3 7 Install Sfuel tank Refer to FUEL TANK in chapter 3 Sfront cowling inner panel left and right Refer to COWLINGS in chapter 3 Sseat Refer to SEAT in chapter 3 ...

Page 264: ... cover Shift shaft cover gasket Dowel pin Oil seal Shift shaft Shift shaft spring Collar Stopper lever spring Circlip Washer 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Drain Refer to CHANGING THE COOLANT in chapter 3 22 Nm 2 2 mSkg 16 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb SHIFT SHAFT ENG EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER ...

Page 265: ...T SHAFT ENG Order Job Part Q ty Remarks 11 12 13 14 Stopper lever Collar Washer Shift shaft spring stopper 1 1 1 1 For installation reverse the removal procedure 22 Nm 2 2 mSkg 16 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 266: ...lace Roller turns roughly Replace the stopper lever EAS00332 INSTALLING THE SHIFT SHAFT 1 Install Sshift shaft spring stopper 1 Swashers Sshift shaft 2 SApply LOCTITE to the threads of the shift shaft spring stopper SHook the ends 3 of the stopper lever spring onto the stopper lever 4 and the crankcase boss SMesh the stopper lever with the shift drum seg ment assembly 2 Install Sshift shaft cover ...

Page 267: ...or cover gasket Dowel pin 1 1 1 2 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to STARTER CLUTCH AND GENERATOR Disconnect 10 Nm 1 0 mSkg 7 2 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 35 Nm 3 5 mSkg 25 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CRANKSHAFT POSITION SENSOR AND PICKUP RO...

Page 268: ...ROTOR ENG Order Job Part Q ty Remarks 5 6 7 Crankshaft position sensor Pickup rotor Plug screw 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 35 Nm 3 5 mSkg 25 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 269: ...bolts are fully loosened remove them 2 Remove Spickup rotor bolt 1 Swasher 2 Spickup rotor 3 While holding the generator rotor 4 with the ro tor holding tool 5 loosen the pickup rotor bolt Sheave holder 90890 01701 YS 01880 A INSTALLING THE PICKUP ROTOR 1 Install Spickup rotor 1 Swasher Spickup rotor bolt When installing the pickup rotor align the groove 2 in the crankshaft sprocket with the point...

Page 270: ...r bolt Sheave holder 90890 01701 YS 01880 A 3 Apply Ssealant onto the crankshaft position sensor lead grommet Yamaha bond No 1215 90890 85505 ACC 11001 5 01 4 Install Spickup rotor cover Sgasket New SWhen installing the pickup rotor cover align the timing chain guide intake side pin 1 with the hole 2 in the pickup rotor cover STighten the pickup rotor cover bolts in stages and in a crisscross patt...

Page 271: ...ch cover gasket Dowel pin 1 1 1 1 1 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CLUTCH ENG YAMAHA BOND No 1215 EAS00273 CLUTCH CLUTCH COVER ...

Page 272: ...isassembling the clutch cover Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer 2 1 1 1 1 1 2 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 ...

Page 273: ... Friction plate Brown Clutch plate t 2 0 mm 0 08 in Friction plate Clutch plate t 2 3 mm 0 09 in Clutch boss nut Lock plate Clutch boss Thrust plate 6 1 1 1 6 7 2 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 90 Nm 9 0 mSkg 65 ftSlb 8 Nm 0 8 mSkg 5 8 ftSlb CLUTCH ENG EAS00274 CLUTCH ...

Page 274: ...ressure plate 2 Spull rod 3 Sfriction plates Sclutch plates 3 Straighten the lock washer tab 4 Loosen Sclutch boss nut 1 While holding the clutch boss 2 with the univer sal clutch holder loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 5 Remove Sclutch boss nut 1 Slock washer 2 Sclutch boss 3 Sthrust plate 4 EAS00280 CHECKING THE FRICTION PLATES The following procedure appli...

Page 275: ...ATES The following procedure applies to all of the clutch plates 1 Check Sclutch plate Damage Replace the clutch plates as a set 2 Measure Sclutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit 0 1 mm 0 0039 in EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch spring...

Page 276: ...lutch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Sbearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check Sclutch boss splines Damage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE P...

Page 277: ...pull rod bearing Damage wear Replace EAS00299 INSTALLING THE CLUTCH 1 Install Sthrust plate 1 Sclutch boss 2 Slock washer 3 New Sclutch boss nut 4 While holding the clutch boss 2 with the clutch holding tool 5 tighten the clutch boss nut Universal clutch holder 90890 04089 YM 91042 3 Bend the lock washer tab along a flat side of the nut 4 Lubricate Sfriction plates Sclutch plates with the recommen...

Page 278: ...as shown in the illustration Clutch plate 1 t 2 3 mm 0 09 in Clutch plate 2 t 2 0 mm 0 08 in Friction plate 3 Friction plate 4 Color Brown 6 Install Spressure plate 1 Align the punch mark b in the pressure plate with the punch mark a in the clutch boss 7 Install Sbearing 1 Spull rod 2 Spressure plate 3 Sclutch springs Sclutch pressure plate screw Tighten the clutch spring bolts in stages and in a ...

Page 279: ...ybdenum disulfide grease onto the pull rod SWhen installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged STighten the clutch cover bolts in stages and in a crisscross pattern 10 Adjust Sclutch cable free play Refer to ADJUSTING THE CLUT...

Page 280: ...il strainer gasket 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to CHANGING THE COOLANT in chapter 3 Refer to ENGINE Refer to WATER PUMP in chapter 6 Disconnect 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 43 Nm 4 3 mSkg 31 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb...

Page 281: ...ly Dowel pin Relief valve assembly 1 1 1 2 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 43 Nm 4 3 mSkg 31 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb OIL PAN AND OIL PUMP ENG ...

Page 282: ... pump assembly Oil pump cover Pin Oil pump inner rotor Oil pump outer rotor Pin Washer Oil pump rotor housing Oil pump driver sprocket 1 2 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 283: ...NG THE OIL PUMP 1 Check Soil pump driven gear 1 Soil pump rotor housing 2 Soil pump cover Cracks damage wear Replace the de fective part s 2 Measure Sinner rotor to outer rotor tip clearance a Souter rotor to oil pump housing clearance b 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 03 X 0 09 mm 0 0012 X 0 0035 in Limit 0 15 mm 0 0059 in Outer rotor to o...

Page 284: ...THE OIL DELIVERY PIPE AND OIL PIPE 1 Check Soil delivery pipe 1 Soil pipe 2 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check Soil strainer 1 Damage Replace Contaminants Clean with solvent EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Soil nozzle 1 Damage wear Replace the oil nozzle SO ...

Page 285: ...2 Install Soil pump housing 1 Soil pump shaft 2 Swasher 3 Spin 4 Sinner rotor 5 Souter rotor 6 Sdowel pins 7 Soil pump cover 8 When installing the inner rotor align the pin 4 in the oil pump shaft with the groove in the inner ro tor 5 3 Check Soil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install Soil pump drive chain Sgear cover Soil pump After tightening th...

Page 286: ...er housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine EAS00380 INSTALLING THE OIL PAN 1 Install Soil pipe Soil delivery pipe 2 Install Sdowel pins Sgasket New Soil pan 1 Soil level switch 2 Sengine oil drain bolt Always use new copper washers STighten the oil pan bolts in stages and in a crisscross ...

Page 287: ...hain Oil pump drive chain Oil pump drive chain guide Lower crankcase Dowel pin 1 1 1 1 3 Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to STARTER CLUTCH AND GENERATOR Refer to SHIFT SHAFT Refer to CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR Refer to CLUTCH Refer to WATER PUMP in chapter 6 Refer to OIL PAN AND OIL PUMP 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ...

Page 288: ...5 63 Order Job Part Q ty Remarks 6 7 8 Thrust plate Washer Plate 1 1 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CRANKCASE ENG ...

Page 289: ...115 mm 4 5 in bolts 8 9 M8 65 mm 2 6 in bolts 11 12 M6 65 mm 2 6 in bolts 13 14 M6 55 mm 2 2 in bolts 15 22 X 26 M6 45 mm 1 8 in bolts 16 19 20 M6 65 mm 2 6 in bolts 17 27 M6 75 mm 3 0 in bolt 18 M6 100 mm 3 9 in bolts 21 3 Remove Slower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slo...

Page 290: ...s then rotate the inner race with your finger Rough movement Replace 2 Check Soil seals Damage wear Replace CHECKING THE TIMING CHAIN 1 Check Stiming chain 2 Damage stiffness Replace the timing chain and crankshaft sprocket as a set Soil water pump assembly drive chain 1 Damage stiffness Replace the oil water pump assembly drive chain and oil water pump assembly drive sprocket as a set ASSEMBLING ...

Page 291: ...olts SLubricate the bolt threads with engine oil SInstall a washer on bolts 1 X 10 SSeal bolt 18 STighten the bolts in the tightening sequence cast on the crankcase M8 85 mm 3 3 in bolts 1 X 7 10 M8 115 mm 4 5 in bolts 8 9 M8 65 mm 2 6 in bolts 11 12 M6 65 mm 2 6 in bolts 13 14 M6 55 mm 2 2 in bolts 15 22 X 26 M6 45 mm 1 8 in bolts 16 19 20 M6 65 mm 2 6 in bolts 17 27 M6 75 mm 3 0 in bolt 18 M6 10...

Page 292: ...end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring 4 4 4 8 4 4 4 4 4 4 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure 15 Nm 1 5 mSkg 11 ftSlb 150_ CONNECTING RODS AND PISTONS ENG EAS00252 CONNECTING RODS AND PISTONS ...

Page 293: ...ton pin 2 Spiston 3 Do not use a hammer to drive the piston pin out SFor reference during installation put identifica tion marks on the piston crown SBefore removing the piston pin deburr the pis ton pin clip groove and the piston pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 YU ...

Page 294: ...r bearing so that it can be reinstalled in its original place EAS00261 CHECKING THE CYLINDER AND PISTON 1 Check Spiston wall Scylinder wall Vertical scratches Replace the cylinder and the piston and piston rings as a set 2 Measure Spiston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge Measure cylinder bore C by taking side to side and front to back measurements of the...

Page 295: ... size P 65 475 X 65 490 mm 2 5778 X 2 5783 in d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 010 X 0 035 mm 0 0004 X 0 0014 in Limit 0 055 mm 0 0022 in f If out of specification replace the cylinder and t...

Page 296: ... Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 25 X 0 35 mm 0 0098 X 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring 0 7 X 0 8 mm 0 0276 X 0 0315 in Limit 1 15 mm 0 0453 in Oil ring 0 10 X 0 35 mm 0 0039 X 0 0138 in CHECKING THE PISTON PINS The ...

Page 297: ...16 043 mm 0 6316 in 4 Calculate Spiston pin to piston clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston clearance Piston pin bore size Piston pin outside diameter Piston pin to piston clearance 0 002 X 0 022 mm 0 0001 X 0 0009 in Limit 0 072 mm 0 0028 in CHECKING THE BIG END BEARINGS 1 Measure Scrankshaft pin to big end bearing clear ance Out of specifi...

Page 298: ... and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves SDo not move the connecting rod or crankshaft until the clearance measurement has been completed SLubricate the bolt threads and nut seats...

Page 299: ...rther to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the nut and then retighten it Replace the bolt with a new one and perform the procedure again SDo not use a torque wrench to tighten the nut to the specified angle STighten the nut until it is at the specified angles When using a hexagonal nut note that the angle from one corner to anothe...

Page 300: ... connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re spectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 5 2 3 brown BIG END BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons 1 Install Stop ring 1 S2nd ring 2 Supper oil ring rail 3 Soil ring expan...

Page 301: ...er to the illustra tion SReinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Spiston Spiston rings Scylinder with the recommended lubricant Recommended lubricant Engine oil 4 Offset Spiston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5 Lubricate Scrankshaft pins Sbig end bearings Sconnect...

Page 302: ... connecting rod assembly into the cylinder with the other hand SMake sure that the Y marks a on the con necting rods face towards the left side of the crankshaft SMake sure that the characters b on both the connecting rod and connecting rod cap are aligned 7 Align Sbolt heads with the connecting rod caps 8 Tighten Sconnecting rod nuts a Replace the connecting rod bolts and nuts with new ones Tight...

Page 303: ... more than the spe cified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again SDo not use a torque wrench to tighten the nut to the specified angle STighten the nut until it is at the specified angles When using a hexagonal nut note that the angle from one corner to another is 60_ ...

Page 304: ...ting rod caps Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS For installation reverse the removal procedure CRANKSHAFT ENG EAS00381 CRANKSHAFT ...

Page 305: ...nkshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 028 X 0 052 mm 0 0011 X 0 0020 in Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed...

Page 306: ...kcase halves SAlign the projections a of the crankshaft jour nal lower bearings with the notches b in the lower crankcase SDo not move the crankshaft until the clearance measurement has been completed f Tighten the bolts to specification in the tight ening sequence cast on the crankcase Crankcase bolt Bolt 1 X 10 1st 12 Nm 1 2 mSkg 8 7 ftSlb 2nd 25 Nm 2 5 mSkg 18 ftSlb 3rd 27 Nm 2 7 mSkg 20 ftSlb ...

Page 307: ...nd the numbers 1 stamped into the low er crankcase are used to determine the re placement crankshaft journal bearing sizes S J1 X J5 refer to the bearings shown in the crankshaft illustration SIf J1 X J5 are the same use the same size for all of the bearings SIf the size is the same for all J1 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J1 and crank ...

Page 308: ...r bearings 1 into the upper crankcase SAlign the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase SBe sure to install each crankshaft journal up per bearing in its original place 2 Install Scrankshaft 3 Install Scrankcase lower Refer to CRANKCASE ...

Page 309: ... Shift drum retainer Shift fork guide bar Spring Shift fork L Shift fork R Shift drum assembly Shift fork C 1 1 1 1 1 2 4 1 1 1 1 Remove the part in the order listed Separate Refer to CRANKCASE 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb TRANSMISSION ENG EAS00419 TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS ...

Page 310: ...Remarks 12 13 14 15 16 Main axle assembly Oil pipe Oil baffle plate Thrust plate Washer 1 1 1 1 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb ...

Page 311: ... pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TRANSMISSION ENG ...

Page 312: ...5 87 Order Job Part Q ty Remarks Bearing housing Bearing 1 1 For installation reverse the removal procedure 15 16 TRANSMISSION ENG ...

Page 313: ...1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TRANSMISSION ENG ...

Page 314: ...G Order Job Part Q ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 15 16 17 18 19 20 21 22 23 24 ...

Page 315: ...the main axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Sshift fork cam follower 1 Sshift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Sshift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a bent shift fork guide b...

Page 316: ...NG THE TRANSMISSION 1 Measure Smain axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 02 mm 0 0008 in 2 Measure Sdrive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Drive axle runout limit 0 02 mm 0 0008 in 3 Check Stransmission gears Blue discoloration pitting wear Replace the...

Page 317: ...1 Install Soil pipe 1 Smain axle assembly 2 with the Torx wrench T30 Make sure to caulk the bolts at three positions after installing the bearing housing 2 Install Sshift fork C 3 Sshift drum assembly 4 Sshift fork guide bar SThe embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L SCarefully position the shift forks so that they...

Page 318: ...drum retainer SInstall shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle SMake sure that the drive axle bearing circlip a is inserted into the grooves in the upper crank case 4 Check Stransmission Rough movement Repair Oil each gear shaft and bearing thoroughly ...

Page 319: ......

Page 320: ...COOL 6 ...

Page 321: ...R 6 4 OIL COOLER 6 5 CHECKING THE OIL COOLER 6 7 INSTALLING THE OIL COOLER 6 7 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 9 INSTALLING THE THERMOSTAT 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 14 ASSEMBLING THE WATER PUMP 6 14 INSTALLING THE WATER PUMP 6 16 ...

Page 322: ...COOL ...

Page 323: ...se Radiator inlet hose Oil cooler outlet hose Radiator Radiator cap 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect Disconnect 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb RADIATOR ...

Page 324: ...6 2 RADIATOR COOL Order Job Part Q ty Remarks 9 Radiator fan 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb ...

Page 325: ...ening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 93 X 123 kPa 0 93 X 1 23 kg cm2 13 2 X 17 5 psi a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 b Apply the specified pressure for ten seconds and make sure there i...

Page 326: ...ling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check Scooling system Leaks Repair or replace any faulty part 4 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 327: ...ion bolt Washer Oil cooler O ring Oil cooler inlet hose Oil cooler inlet pipe Water jacket joint hose Water jacket joint 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to RADIATOR Drain Refer to CHANGING THE ENGINE OIL in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb 63 Nm 6 3 mSkg 46 ftSlb OIL COOLER COOL EAS00457 OIL COOLER ...

Page 328: ...OIL COOLER COOL Order Job Part Q ty Remarks 10 11 12 O ring Water pump outlet hose Radiator outlet hose 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 63 Nm 6 3 mSkg 46 ftSlb ...

Page 329: ...ew Sunion bolt 3 SBefore installing the oil cooler lubricate the union bolt and O ring with a thin coat of engine oil SMake sure the O ring is positioned properly 3 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Fill Scrankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapte...

Page 330: ...nlet hose Thermostat cover Thermostat 1 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS Refer to FUEL TANK Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to THROTTLE BODIES in chapter 7 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb THERMOSTAT COOL EAS00460 THERMOSTAT ...

Page 331: ...wly heat the water c Place a thermometer in the water d While stirring the water observe the thermo stat and thermometer s indicated tempera ture 1 Thermometer 2 Water 3 Thermostat 4 Container A Fully closed B Fully open If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Sthermostat cover Cracks damage Replace ...

Page 332: ...the thermostat cover to the cyl inder head lubricate the O ring with a thin coat of lithium soap based grease 3 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check Scooling system Leaks Repair or replace any faulty part 5 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CH...

Page 333: ...move the parts in the order listed It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect For installation reverse the removal procedure NOTE 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb WATER PUMP COOL EAS00468 WATER PUMP ...

Page 334: ...ver O ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O ring Copper washer 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 10 Nm 1 0 mSkg 7 2 ftSlb 8 9 10 WATER PUMP COOL ...

Page 335: ...from the outside of the water pump housing 2 Water pump housing 3 Remove Soil seal 1 with a thin flat head screwdriver Remove the oil seal from the outside of the wa ter pump housing 4 Remove Sbearing 1 Remove the bearing from inside of the water pump housing 5 Remove Srubber damper holder 1 Srubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft ...

Page 336: ...s damage wear Replace EAS00475 ASSEMBLING THE WATER PUMP 1 Install Sbearing Soil seal New 1 into the water pump housing 2 SBefore installing the oil seal apply tap water or coolant onto its out surface SInstall the oil seal with a socket that matches its outside diameter 2 Install Swater pump seal New 1 Never lubricate the water pump seal surface with oil or grease SInstall the water pump seal wit...

Page 337: ... 3 Install Srubber damper New 1 Srubber damper holder New 2 Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Simpeller shaft tilt Out of specification Repeat steps 3 and 4 Make sure the rubber damper and rubber damper holder are flush with the impeller Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller 5 Install Simpeller shaft Scirc...

Page 338: ...outlet hose 2 SInstall the radiator outlet hose with white a mark positioned outside SInstall the hose clamp with its screw head pointed to the inner side 3 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check Scooling system Leaks Repair or replace any faulty part 5 Measure Sradiator cap opening pressure Below the specified ...

Page 339: ......

Page 340: ...NG CHART 7 6 DIAGNOSTIC MODE 7 7 TROUBLESHOOTING DETAILS 7 13 THROTTLE BODIES 7 25 INJECTORS 7 26 CHECKING THE INJECTORS 7 27 CHECKING THE THROTTLE BODIES 7 27 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 28 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 29 AIR INDUCTION SYSTEM 7 31 AIR INJECTION 7 31 AIR CUT OFF VALVE 7 31 AIR INDUCTION SYSTEM DIAGRAMS 7 32 CHECKING THE AIR IN...

Page 341: ...FI ...

Page 342: ... Intake air pressure sensor 8 Throttle position sensor 9 Fuel injector 10 Catalytic converter 11 Crankshaft position sensor 12 Coolant temperature sensor 13 Spark plug 14 Pressure regulator 15 Battery 16 ECU 17 Fuel injection system relay 18 Engine trouble warning light 19 Lean angle cut off switch FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ...

Page 343: ...cut off switch 18 Crankshaft position sensor 19 Intake air temperature sensor 20 Coolant temperature sensor 21 ECU 22 Cylinder 1 injector 23 Cylinder 2 injector 24 Cylinder 3 injector 25 Cylinder 4 injector 27 Speed sensor 28 Ignition coil 1 and 4 29 Ignition coil 2 and 3 30 Spark plug 34 Engine trouble warning light 36 Multi function meter 43 Engine stop switch 50 Fuse ignition FUEL INJECTION SYS...

Page 344: ...ting an engine trouble warning light SAfter the engine has been stopped the lowest fault code number appears on the LCD meter Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted EAS00900 Engine trouble warning light indication and FI system operating condition Warning light indication ECU s operation FI operation Vehicle operation Flashing Warning pr...

Page 345: ...emperature sensor Intake temperature sensor open or short circuit detected S Fixes the intake temperature to 20_C Able Able 33 Faulty ignition Open circuit detected in the primary lead of the ignition coil 1 4 S Cut the injection of other cylinder in the same group with the cylinder that the error is detected Example when the 1 cylinder is defective cut the in Able depending on the num Able depend...

Page 346: ...able Er 2 ECU internal malfunction output signal error No signals are received from the ECU within the specified duration Unable Unable Er 3 ECU internal malfunction output signal error Data from the ECU cannot be received correctly Unable Unable Er 4 ECU internal malfunction input signal error Non registered data has been received from the meter Unable Unable ...

Page 347: ...o OFF turn the mainswitch back to ON and then check if the fault code num ber is still displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer to the Diagnostic mode table Diagnostic code No 62 Repairs completed The engine trouble warning light does not come on Check the op...

Page 348: ...t the clock and tripmeter displays S dIAG appears on the LCD meter 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 se conds or more to execute the selection 6 Select the diagnostic code number that ap plies to the item that was verified with the fault code number by pressing the...

Page 349: ...rs on the trip LCD SActuator operation Set the engine stop switch to ON to operate the actuator If the engine stop switch is set to ON set it to OFF and then set it to ON again 8 Turn the main switch to OFF to cancel the the diagnostic mode To perform a reliable diagnosis make sure to turn OFF the power supply before every check and then start right from the beginning ...

Page 350: ...lled sensor 06 22 Intake air temperature sensor open or short circuit detected S Open or short circuit in wiring harness S Defective intake temperature sensor S Malfunction in ECU S Improperly installed sensor 05 30 The motorcycle has overturned S Overturned S Malfunction in ECU 08 33 Open circuit is detected in the primary lead of the ignition coil 1 4 S Open circuit in wiring harness S Malfuncti...

Page 351: ...om the ECU S Open or short circuit in wiring sub lead S Malfunction in meter S Malfunction in ECU Er 2 No signals are received from the ECU within the specified duration S Improper connection in wiring sub lead S Malfunction in meter S Malfunction in ECU Er 3 Data from the ECU cannot be received correctly S Improper connection in wiring sub lead S Malfunction in meter S Malfunction in ECU Er 4 Non...

Page 352: ...oltage Displays the fuel system voltage battery voltage Engine stop switch is on 0 X 18 7 V Normally approximately 12 0 V 20 Sidestand switch Displays that the switch is ON or OFF When the gear is in a position other than neutral Stand retracted ON Stand extended OFF 21 Neutral switch Displays that the switch is ON or OFF Neutral ON In gear OFF 30 Ignition coil 1 4 After 1 second has elapsed from ...

Page 353: ...At that time the fan motor rotates 52 Headlight relay 1 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON it actuates the headlight relay five times every 5 seconds and illuminates the engine trouble warning light ON 2 seconds OFF 3 seconds If the engine stop switch is ON turn it OFF once and then turn it back ON Check the headlight relay operating soun...

Page 354: ...rmal signals are received from the crankshaft position sensor Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of sensor Check the installed area for looseness or pinching Reinstated by cranking the 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check...

Page 355: ... out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Intake air pressure sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black B...

Page 356: ... 01 throttle position sensor Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of throttle position sensor Check the installed area for looseness or pinching Check that it is installed in the specified position Refer to THROTTLE BODIES section Reinstated by turning the main switch ON 2 Connected condition of connector In...

Page 357: ...re is a malfunction repair it and connect it securely If the transmis sion is in gear it is reinstated by retracting the sidestand If the transmis sion is in neu tral it is rein 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open circuit Sidestand switch signal input line of ECU coupler black red tral it is rein stated by re connecting the wiring Fault c...

Page 358: ...or pinching Reinstated by turning the 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Intake air temperature sensor coupler Main wiring harness ECU coupler Sub wire harness coupler mainswitch ON 3 Open or short circuit in wiring harness and or sub lead...

Page 359: ...ect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Lean angle cut off switch coupler Main wiring harness ECU coupler ON however the engine can not be re started unless the main switch is first turned 4 Defective lean angle cut off switch Execute the diagnostic mode code No 08 Replace if defect...

Page 360: ... have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Ignition coil primary side coupler gray black Main wiring harness ECU coupler Sub wire harness coupler Reinstated by starting the en gine and oper ating it at idle In case of mul ti l li d 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit...

Page 361: ...0 to 30 km h A3 Gear for detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 A4 Defective speed sensor Execute the diagnostic mode code No 07 Replace if defective 1 Measure the speed sensor output voltage 2 Connect the pocket tester DC 20 V to the speed sensor coupler terminal as shown 3 Measure the speed sensor output voltage 4 Is the speed sensor OK Order I...

Page 362: ...r it and connect it securely Starting circuit cut off relay coupler fuel injection system relay Fuel pump coupler Injector coupler ECU coupler Reinstated by starting the engine and operating it at idle 2 Malfunction in ECU Fuel injection system relay is on 3 Open or short circuit in the wiring har ness Repair or replace if there is an open or short circuit Between starting circuit cut off relay fu...

Page 363: ...d countermeasure Reinstatement method 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely ECU coupler Reinstated by starting the en gine and oper ating it at idle 2 Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BAT TERY in...

Page 364: ...have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON and receives a 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between meter coupler and ECU coupler yellow blue yello...

Page 365: ...ve pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON and receives a 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between meter coupler and ECU coupler yellow blue yellow ...

Page 366: ...w Throttle bodies Throttle cable Throttle body joint Heat protector 2 1 4 1 2 4 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to BATTERY BOX AND BATTERY BOX BRACKET in chapter 3 Disconnect Disconnect Disconnect For in...

Page 367: ...er Cylinder 2 injector coupler Cylinder 3 injector coupler Cylinder 4 injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Throttle position sensor Fuel pulsation damper Throttle body assembly 1 1 1 1 1 1 1 1 1 1 4 1 1 1 Remove the parts in the order listed Disconnect Disconnect For installation reverse the removal pro cedure EAS00910 INJECT...

Page 368: ...3 CHECKING THE THROTTLE BODIES 1 Check Sthrottle bodies Cracks damage Replace the throttle bo dies as a set 2 Check Sfuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with com pressed air Sfuel pulsation damper Do not adjust the fuel pulsation damper ...

Page 369: ...ank Refer to SEAT AND FUEL TANK in chapter 3 b Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe Pressure gauge 90890 03153 YU 03153 Adapter 90890 03176 YM 03176 c Install the fuel tank Refer to FUEL TANK in chapter 3 d Start the engine e Measure the fuel pressure Fuel pressure 250 kPa 2 5 kg cm2 36 3 psi Faulty Replace the fuel pump assembly ...

Page 370: ... the throttle body c Connect the pocket tester Ω 1k to the throttle position sensor Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 d Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor Maximum throttle position sensor resistance 3 5 X 6 5 kΩ at 20_C 68_F blue black blue e Connect the pocket tester Ω 1...

Page 371: ... ings from closed to wide open throttle may dif fer slightly from those specified Throttle position sensor resistance 0 X 5 1 5 kΩ at 20_C 68_F yellow black blue 2 Adjust Sthrottle position sensor angle a Connect the throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the throttle position sensor Digital circuit tester 90890 03174 c Measure the throttle pos...

Page 372: ...ned exhaust gases is approximately 600 to 700_C 1112 to 1292_F EAS0097 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant tempera ture is below the specified...

Page 373: ...7 32 AIR INDUCTION SYSTEM FI A To cylinder 1 and 2 B To cylinder 3 and 4 1 Air cut off valve 2 Reed valve 3 To air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 374: ...damage Replace Spipes Cracks damage Replace 2 Check S reed valve 1 S reed valve stopper Sreed valve seat Cracks damage Replace the reed valve 3 Measure S reed valve bending limit a Out of specification Replace the reed valve Reed valve bending limit 0 4 mm 0 016 in 1 Surface plate 4 Check Sair cut off valve Cracks damage Replace ...

Page 375: ...er from the wire harness b Connect the pocket tester Ω 1 to the AI system solenoid terminal as shown Tester positive probe brown red 1 Tester negative probe red white 2 c Measure the AI system solenoid resistance AI system solenoid resistance 18 X 22 Ω at 20_C 68_F d Out of specification Replace ...

Page 376: ...ELEC 8 ...

Page 377: ...OOTING 8 9 ELECTRIC STARTING SYSTEM 8 14 CIRCUIT DIAGRAM 8 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 15 TROUBLESHOOTING 8 16 STARTER MOTOR 8 19 CHECKING THE STARTER MOTOR 8 21 ASSEMBLING THE STARTER MOTOR 8 22 CHARGING SYSTEM 8 24 CIRCUIT DIAGRAM 8 24 TROUBLESHOOTING 8 25 LIGHTING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 CHECKING THE LIGHTING SYSTEM 8 31 SIGNALING SYSTEM 8 34 CIR...

Page 378: ...L PUMP 8 51 IMMOBILIZER SYSTEM 8 52 SYSTEM DIAGRAM 8 52 CIRCUIT DIAGRAM 8 53 GENERAL INFORMATION 8 54 KEY ID REGISTRATION METHOD 8 55 SELF DIAGNOSIS ERROR CODE INDICATION 8 57 TROUBLESHOOTING 8 58 CHECKING THE IMMOBILIZER SYSTEM 8 59 REPLACEMENT PARTS ON TROUBLES 8 61 SELF DIAGNOSIS 8 62 TROUBLESHOOTING 8 63 ...

Page 379: ...10 Radiator fan motor 11 Horn 12 Ignition coil 1 Main switch immobilizer unit 2 Front brake light switch 3 Starter relay 4 Battery 5 Fuse box 6 Rear brake light switch 7 Neutral switch 8 Sidestand switch EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...

Page 380: ...ectifier regulator 12 Throttle position sensor 1 Coolant temperature sensor 2 Intake air temperature sensor 3 Intake air pressure sensor 4 Fuel pump 5 ECU 6 Lean angle cut off switch 7 Starting circuit cut off relay 8 Dimmer relay ELECTRICAL COMPONENTS ELEC ...

Page 381: ...to 0 and to the Ω 1 range SWhen checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a...

Page 382: ...7 Sidestand switch 8 Engine stop switch 9 Front brake light switch 10 Start switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 383: ... and usually use a bulb holder that must be detached before removing the bulb The ma jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise SBulbs C are used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise CHECKING THE CONDITION OF THE BULBS The following procedure applies...

Page 384: ...quer thinner 2 Check Sbulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 YU 3112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 and check the continuity b Connect the positive tester probe to terminal 1 and the negative tester probe t...

Page 385: ...lies to all of the LEDs 1 Check SLED for proper operation Improper operation Replace a Disconnect the meter assembly coupler me ter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal As for connecting with which coupler terminal refer to CABLE ROUTING in chapter 2 SA wire that is used as a jumper lead must have at least the same capacity of t...

Page 386: ...idestand switch 13 Neutral switch 17 Lean angle cut off switch 18 Crankshaft position sensor 21 ECU 28 Ignition coil 1 and 4 29 ignition coil 2 and 3 30 Spark plug 43 Engine stop switch 50 Fuse ignition 57 Clutch switch IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 387: ...ITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 spark plug cap resistanc...

Page 388: ...owing procedure applies to all of the spark plug caps SRemove the spark plug cap from the spark plug lead SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance YES NO Spark plug cap resistance 10 kΩ at 20_C 68_F SIs the spark plug cap OK Replace the spark plug cap EAS00747 6 Ignition coil resistance The following procedure applies to all of the ignit...

Page 389: ...asure the crankshaft position sensor re sistance EAS00748 Crankshaft position sensor resis tance 248 X 372 Ω at 20_C 68_F between gray and black SIs the crankshaft position sensor OK YES NO Replace the crank shaft position sen sor EAS00749 8 Main switch SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES NO Replace the main switch EAS00750 9 Engine stop ...

Page 390: ...wn SCheck the starting circuit cut off relay for continuity Positive tester probe black red Negative tester probe sky blue 1 2 EAS00753 Positive tester probe black red Negative tester probe blue green Continuity 1 3 Positive tester probe sky blue Negative tester probe black red 2 1 Positive tester probe blue green Negative tester probe black red No continuity 3 1 YES NO Replace the starting circui...

Page 391: ...754 15 Wiring SCheck the entire ignition system s wiring Refer to CIRCUIT DIAGRAM SIs the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition system s wiring Replace the ECU ...

Page 392: ... Starter motor 10 Battery 11 Starting circuit cut off relay 12 Sidestand switch 13 Neutral switch 43 Engine stop switch 44 Start switch 50 Fuse ignition 57 Clutch switch ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 393: ... relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN ...

Page 394: ...Clean the battery terminals SRecharge or re place the battery EAS00739 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 starter moto...

Page 395: ...ocket tester Ω 1 and battery 12 V to the starter relay coupler as shown YES NO Replace the starter relay Positive battery terminal red white Negative battery terminal blue white Positive tester probe red Negative tester probe black 1 2 3 4 SDoes the starter relay have continuity be tween red and black EAS00749 6 Main switch SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs t...

Page 396: ...he start switch for continuity Refer to CHECKING THE SWITCHES SIs the start switch OK YES NO Replace the right handlebar switch EAS00764 10 Clutch switch SCheck the clutch switch for continuity Refer to CHECKING THE SWITCHES SIs the clutch switch OK YES NO Replace the clutch switch EAS00763 EAS00752 9 Sidestand switch SCheck the sidestand switch for continuity Refer to CHECKING THE SWITCHES SIs th...

Page 397: ...k Throttle bodies Starter motor lead Starter motor 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to COWLINGS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to THROTTLE BODIES in chapter 7 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb EAS00767 STARTER MOTOR ...

Page 398: ...l seal Bearing Washer set Rear cover Washer set O ring Brush holder Armature assembly Starter motor yoke O ring 1 1 1 1 1 1 1 1 2 1 1 1 2 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 11 12 3 4 Nm 0 34 mSkg 2 5 ftSlb 7 8 Nm 0 78 mSkg 5 6 ftSlb 13 EAS00768 ...

Page 399: ...been grounded to fit the commuta tor Mica undercut 0 7 mm 0 03 in The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 03112 YU 3112 Armature coil Commutator resi...

Page 400: ... Replace the brush springs as a set Brush spring force 7 16 X 9 52 N 730 X 971 gf 25 77 X 34 27 oz 7 Check Sgear teeth Damage wear Replace the gear 8 Check Sbearing Soil seal Damage wear Replace the defective part s EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install Sbrush seat 1 2 Install Sarmature 2 SO ring 3 New Align the tab a on the brush seat with the slot b in the starter motor rear cover ...

Page 401: ... Nm 0 34 mSkg 2 5 ftSlb NOTE 3 Install Sstarter motor yoke 1 SO ring 2 New Sfront cover 3 Srear cover 4 Sbolts 5 Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers ...

Page 402: ...8 24 2 A C magneto 3 Rectifier regulator 7 Fuse main 10 Battery CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 403: ...harged NOTE Minimum open circuit voltage 12 8 V or more at 20_C 68_F SIs the battery OK CHARGING SYSTEM ELEC NOTE YES NO 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK Replace the fuse 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00774 TROUBLESHOOTING The battery is ...

Page 404: ...ck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly con nected and without defects Properly connect or repair the charging system s wiring EAS00779 Replace the rectifi er regulator 4 Stator coil lead SDisconnect stator coil lead coupler SConnect the pocket tester Ω 1 to the sta tor coil lead coupler as shown Positive tester pro...

Page 405: ... L B Br B B R W Sb Sb Y L Y L B B R G Y L Lg R W R L R L Gy B Gy B L Br R Br R Br R ON OFF P R B B R B R B P O R B W R L L Y L Y R W Gy Gy R W Br R Br R Br R B L L W Sb Sb Br B Br B B W Y B Y B L L G Y G Y R Y R Y Lg Lg B G L W R W R B B B R Br G Br G Br W Br W R W G W Br W Y P W B L G W Br W Y P W B L R B R L G B L B Y G W L B R B L R W R L Gy Y L Br R G B R B O B W Y Br W P W Y G B W B Y L W B L...

Page 406: ...n 10 Battery 21 ECU 37 High beam indicator light 49 Fuse headlight 50 Fuse ignition 51 Fuse park 54 License plate light 55 Tail brake light 58 Pass switch 59 Dimmer switch 64 Dimmer relay 65 Auxiliary light 66 Headlight high beam 67 Headlight low beam ...

Page 407: ...ING SYSTEM ELEC NOTE YES NO 1 Main headlight ignition and park fuses SCheck the main park ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main park ignition and headlight fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00781 TROUBLESHOOTING Any of the followi...

Page 408: ...r Ω 1 and bat tery 12 V to the dimmer relay as shown Positive battery lead red yellow Negative battery lead yellow black EAS00787 YES NO 7 Wiring SCheck the entire lighting system s wiring Refer to CIRCUIT DIAGRAM SIs the lighting system s wiring properly con nected and without defects Properly connect or repair the lighting system s wiring Check the condition of each of the lighting system s circ...

Page 409: ... the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Low beam Headlight Positive tester probe black Negative tester probe black green 1 2 Meter assembly coupler wire harness side STurn the main switch to ON SStart the engine SSet the dimmer switch to or SMeasure the voltage DC 12 V of black green or black yellow on the headlight coupler wire harness sid...

Page 410: ...icense plate light fails to come on YES NO 2 Voltage SConnect the pocket tester DC 20 V to the license plate light coupler wire harness light side as shown The wiring circuit from the main switch to the license plate light coupler is faulty and must be re paired Positive tester probe blue Negative tester probe black 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of blue on the licens...

Page 411: ...lue on the tail brake light coupler wire harness side SIs the voltage within specification 2 This circuit is OK EAS00791 4 The auxiliary light fails to come on YES NO 1 Auxiliary light and socket SCheck the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the auxiliary light bulb and socket OK Replace the auxiliary light bulb socket or both YES NO 2 ...

Page 412: ...8 34 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 413: ...36 Multi function meter 38 Turn signal indicator light 39 Oil level switch 42 Front brake light switch 48 Fuse signal 50 Fuse ignition 51 Fuse park 52 Turn signal relay 53 Rear brake light switch 55 Tail brake light 60 Hazard switch 61 Turn signal switch 62 Horn switch 63 Horn 68 Rear turn signal light right 69 Rear turn signal light left 70 Front turn signal light right 71 Front turn signal light...

Page 414: ...GHTING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Backup main ignition signal and park fuses SCheck the backup main ignition signal and park fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the backup main ignition signal and park fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit...

Page 415: ...main switch to ON SPull in the brake lever or push down on the brake pedal SMeasure the voltage DC 12 V of yellow on the tail brake light coupler wire harness side SIs the voltage within specification 2 YES NO 2 Voltage SConnect the pocket tester DC 20 V to the horn connector at the horn terminal as shown The wiring circuit from the main switch to the horn connec tor is faulty and must be repaired...

Page 416: ...round Positive tester probe brown green 1 STurn the main switch to ON SMeasure the voltage DC 12 V on brown green at the turn signal relay coupler wire harness side SIs the voltage within specification 1 YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re paired YES NO 4 Voltage SConnect the pocket tester DC 20 V to the turn signal relay coupler...

Page 417: ... ity Refer to CHECKING THE LEDs SAre the neutral indicator light OK EAS00801 4 The neutral indicator light fails to come on YES NO Replace the meter assembly YES NO 2 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK Replace the neutral switch When you switch the positive and negative tester probes the readings in the above chart will ...

Page 418: ...the tester readings correct YES NO 1 Oil level warning light LEDs SCheck the oil level warning light for continu ity When the main switch is turn to ON the oil level warning light is come on SAre the oil level warning light OK Replace the meter assembly EAS00802 5 The oil level warning light fails to come on YES NO 2 Oil level switch SDrain the engine oil and remove the oil level switch from the o...

Page 419: ...EAS00803 6 The fuel level warning light fails to come on 1 Fuel sender SDrain the fuel from the fuel tank and remove the fuel pump from the fuel tank SDisconnect the fuel sender coupler from the wire harness SConnect the pocket tester Ω 10 to the fuel sender terminals as shown Tester positive probe green white Tester negative probe black 1 2 Fuel sender resistance Full position of the float 20 X 2...

Page 420: ...ing circuit from the main switch to the meter assem bly coupler is faulty and must be re paired Positive tester probe green white Negative tester probe black white 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of green white and black white at the meter assembly coupler SIs the voltage within specification This circuit is OK 1 2 ...

Page 421: ...tch 7 Fuse main 10 Battery 20 Coolant temperature sensor 21 ECU 45 Fuse radiator fan motor 46 Radiator fan motor relay 47 Radiator fan motor 50 Fuse ignition COOLING SYSTEM ELEC EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 422: ...radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main ignition and radiator fan motor fuses OK Replace the fuse s EAS00808 TROUBLESHOOTING SThe radiator fan motor fails to turn SThe coolant temperature indicator light fails to light when the engine is warm Check 1 main ignition and radiator fan motor fuses 2 battery 3 main switch 4 radiator fan motor 5 rad...

Page 423: ...tor relay SDisconnect the radiator fan motor relay form the wire harness SConnect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown SCheck the radiator fan motor for continuity Replace the radiator fan motor NO YES Battery positive terminal red white Battery negative terminal green yellow 1 2 SDoes the radiator fan motor relay have conti nuity between brown black ...

Page 424: ... Coolant temperature sensor resistance 0_C 32_F 5 21 X 6 37 kΩ 80_C 176_F 0 29 X 0 35 kΩ WARNING SHandle the coolant temperature sensor with special care SNever subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 6 Coolant temperature sensor Replace the coolant temperature sensor NO YES Coolant temperature sensor 20 Nm 2 0 mSkg 14 ftSlb T...

Page 425: ...in switch 5 Fuse fuel injection 7 Fuse main 10 Battery 11 Starting circuit cut off relay 14 Fuel pump 21 ECU 43 Engine stop switch 50 Fuse ignition FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 426: ... Fuse main 3 Main switch 4 Fuse ignition 5 Engine stop switch 6 ECU 7 Fuse fuel injection 8 Starting circuit cut off relay fuel injection system relay 9 Fuel pump EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump ...

Page 427: ...andlebar switch SIs the engine stop switch OK NOTE YES NO 1 Main ignition and fuel injection system fuses SCheck the main ignition and fuel system fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 Replace the fuse s SAre the main ignition and fuel injection sys tem fuses OK EAS00816 TROUBLESHOOTING If the fuel pump fails to operate Check 1 main ignition and fuel injection fuses 2 batt...

Page 428: ... starting circuit cut off relay have continuity between red and red blue YES NO 6 Fuel pump resistance SDisconnect the fuel pump coupler from the wire harness SConnect the pocket tester Ω 1 to the fuel pump coupler as shown Properly connect or repair the fuel sys tem s wiring 1 2 Positive tester probe red blue Negative tester probe black EAS00817 YES NO Fuel pump resistance 0 2 X 3 0 Ω at 20_C 68_...

Page 429: ...do accidentally spill gasoline wipe it up immediately with dry rags SIf gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Check SFuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Connect the battery DC 12 V to the fuel pump coupler as shown Positive ba...

Page 430: ...OBILIZER SYSTEM ELEC Br Brown Lg Light green Br L Brown Blue R G Red Green R W Red White Y L Yellow Blue 1 MAIN SWITCH AND IMMOBILIZER UNIT 2 IMMOBILIZER INDICATOR LIGHT 3 ECU IMMOBILIZER SYSTEM SYSTEM DIAGRAM ...

Page 431: ...8 53 1 Main switch 4 Fuse backup 6 Immobilizer unit 7 Fuse main 10 Battery 21 ECU 32 Immobilizer indicator light 36 Multi function meter 50 Fuse ignition IMMOBILIZER SYSTEM ELEC CIRCUIT DIAGRAM ...

Page 432: ...ere the temperature may rise SDo not put it in the water when washing clothes for example SDo not place it near a magnet or a loud speaker SIf all keys are missing the engine control unit ECU is required to replace together with the keys and the immobilizer unit SImmobilizer unit cannot be operated with the copy key until the transponder code of the code re regis tering key is registered to the im...

Page 433: ...ndicator light shows the standby mode To initiate the standby mode turn OFF the main switch and then it will be the standby mode when it passes 30 seconds When 24 hours passed the standby mode ends and the indicator light stops flashing b After the main switch is turned ON with the code re registering key within 5 seconds turn OFF the main switch and then turn ON the main switch with the standard ...

Page 434: ...gistered standard key Flashing ends when the registration of the seconds unregistered standard key is complete e When the registration is finished the indicator light goes off f Check that the engine can be started with the registered two standard keys Important note If you lost a standard key immediately re register your code re registering key and the remaining stan dard key if any This will del...

Page 435: ...Obstruction due to radio wave noise 2 Error by disconnection of the communication harness 3 Immobilizer unit failure 4 ECU failure 1 Check the wire harness and con nector 2 Replace the immobilizer unit 3 Replace the ECU 54 Immobilizer Codesdonotmatchbetween ECU and immobilizer unit Noise interference or disconnected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnection of the c...

Page 436: ...e immobiliz er system s wiring Check the condition of each of the immo bilizer system s cir cuits Refer to CHECK ING THE IMMOBI LIZER SYSTEM IMMOBILIZER SYSTEM ELEC NOTE YES NO 1 Main ignition and backup fuses SCheck the main ignition and backup fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main ignition and back up fuses OK Replace the fuse s EAS00794 TROUBLESHOOTING SWh...

Page 437: ...m indicator light lead OK YES NO The wiring circuit from the meter to im mobilizer unit is faulty and must be repaired Replace the immobi lizer unit 1 Voltage SConnect the pocket tester DC 20 V to the meter coupler as shown 3 LCD display Positive tester probe red white or red green Negative tester probe black white 2 3 2 YES NO The wiring circuit from the main switch to the immobilizer unit couple...

Page 438: ...t failure or ECU failure Check the signal lead yellow blue between the immobilizer unit and ECU connector Yellow blue lead is disconnected or short circuited Repair or replace the circuit Correct Replace the immobilizer unit Failure Turn ON the main switch with code re registering key and check the indi cator Failure Two standard key Transpond er defective Register again Failure Replace the key 2 ...

Page 439: ...re is no parts setting as a single unit It will be the replacement in a set with the IMMOBILIZER UNIT 2 Accessory lock means the seat lock fuel filler cap or the helmet holder STo replace the single unit of ECU first turn ON the main switch with the code re registering key This operation allows the code re registering key ID to be registered to the new ECU Register the stan dard key subsequently S...

Page 440: ... warning light when the main switch is turned ON irrespective of whether the engine is running or not Circuit Defect s System response Condition code Fuel pump thermistor SOpen circuit SShort circuit SThe fuel warning light indicate the condition code Refer to 1 Oil level gauge SOpen circuit SShort circuit SThe oil level warning light indicate the condition code Refer to 2 1 Condition code Fuel wa...

Page 441: ...on SIs the fuel pump thermistor OK YES Replace the fuel pump Replace the multi function meter NOTE 14 Fuel pump 36 Multi function meter TROUBLESHOOTING The warning light starts to indicate the self diagnosis sequence Check 1 fuel pump thermistor 2 oil level switch SBefore troubleshooting remove the following part s 1 seat 2 front cowling inner panel left and right 3 fuel tank STroubleshoot with th...

Page 442: ...e oil level warning light fails to come on SIs the oil level switch OK YES Repair or replace the wire harness NO 1 Wire harness SCheck the wire harness for continuity Refer to CIRCUIT DIAGRAM SIs the wire harness OK YES Replace the multi function meter 36 Multi function meter 39 Oil level switch 2 Oil level switch CIRCUIT DIAGRAM ...

Page 443: ...9 TRBL SHTG ...

Page 444: ...CE 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNC...

Page 445: ... NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT COME ON 9 6 TURN SIGNAL BLINKS SLOWLY 9 6 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 HORN DOES NOT SOUND 9 6 ...

Page 446: ... trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING FAILURES ENGINE Cylinder s and cylinder head s SLoose spark plug SLoose cylinder head or cylinder SDamaged cylinder head gasket SWorn or damaged cylinder SIncorrect valve clearance SImproperly sealed valve SIncorrect valve...

Page 447: ...ensor Switches and wiring SFaulty main switch SFaulty engine stop switch SBroken or shorted wiring SFaulty neutral switch SFaulty start switch SFaulty sidestand switch SFaulty clutch switch SImproperly grounded circuit SLoose connections EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s SIncorrect valve clearance SDamaged valve train components Air filter SClogged air fi...

Page 448: ...rrect oil viscosity high SDeteriorated oil EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft SImproperly adjusted shift rod SBent shift shaft Shift drum and shift forks SForeign object in a shift drum groove SSeized shift fork SBent shift fork guide bar Transmission SSeized transmission gear SForeign object between transmission gears SI...

Page 449: ...oil viscosity SInferior oil quality COOLING SYSTEM Coolant SLow coolant level Radiator SDamaged or leaking radiator SFaulty radiator cap SBent or damaged radiator fin Water pump SDamaged or faulty water pump SThermostat SThermostat stays closed SOil cooler SClogged or damaged oil cooler SHose s and pipe s SDamaged hose SImproperly connected hose SDamaged pipe SImproperly connected pipe EAS00856 OV...

Page 450: ...gh SLoose damper rod assembly bolt SDamaged damper rod assembly bolt copper washer SCracked or damaged cap bolt O ring MALFUNCTION SBent or damaged inner tube SBent or damaged outer tube SDamaged fork spring SWorn or damaged outer tube bushing SBent or damaged damper rod SIncorrect oil viscosity SIncorrect oil level EAS00862 UNSTABLE HANDLING Handlebar SBent or improperly installed handlebar Steer...

Page 451: ...y horn SFaulty main switch SFaulty horn switch SFaulty battery SBlown damaged or incorrect fuse SFaulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON SWrong headlight bulb SToo many electrical accessories SHard charging SIncorrect connection SImproperly grounded circuit SPoor contacts main or light switch SBurnt out headlight bulb HEADLIGHT BULB BURNT OUT SWr...

Page 452: ... position sensor 19 Intake air temperature sensor 20 Coolant temperature sensor 21 ECU 22 Cylinder 1 injector 23 Cylinder 2 injector 24 Cylinder 3 injector 25 Cylinder 4 injector 26 Air cut off valve 27 Speed sensor 28 Ignition coil 1 and 4 29 Ignition coil 2 and 3 30 Spark plug 31 Meter assembly 32 Immobilizer indicator light 33 Oil level warning light 34 Engine trouble warning light 35 Neutral i...

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Page 456: ...wn Green Br L Brown Blue Br R Brown Red Br W Brown White G B Green Black G L Green Blue G W Green White G Y Green Yellow Gy B Gray Black L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow O B Orange Black O R Orange Red P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Ye...

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