Yamaha FZ6-ST Supplementary Service Manual Download Page 390 | Manualshive

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7-20

FUEL INJECTION SYSTEM

FI

Speed sensor output voltage

When sensor is on

DC 4.8 V or more

When sensor is off

DC 0.6 V or less

Tester positive probe

!

white

Tester negative probe

!

black / blue

1

2

Fault code No.

42

Symptom

1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.

Used diagnostic code No. 07 (speed sensor)

!

A1

X

A4

No. 21 (neutral switch)

!

B1

X

B4

Order

Inspection operation item and probable
cause

Operation item and countermeasure

Reinstatement
method

A1

Connected condition of speed sensor
connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the cou-
pler.

If there is a malfunction, repair it and connect it
securely.
Speed sensor coupler

Main wiring harness ECU coupler

Reinstated by
starting the
engine, and
inputting the
vehicle speed
signals by

ti

th

A2

Open or short circuit in speed sensor
lead.

Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler.

blue - blue
white / yellow - white / yellow
black / blue - black / blue

operating the
motorcycle at a
low speed of
20 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

Inspection operation item and probable
cause

Operation item and countermeasure

Reinstatement
method

B1

Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the cou-
pler.

If there is a malfunction, repair it and connect it
securely.

Neutral switch connector
Main wiring harness ECU coupler

Reinstated by
starting the
engine, and
inputting the
vehicle speed

i

l b

B2

Open or short circuit in neutral switch
lead.

Repair or replace if there is an open or short
circuit.
Between switch connector and ECU coupler

sky blue - black / yellow

signals by
operating the
motorcycle at a
low speed of
20 to 30 km / h

B3

Faulty shift drum
(neutral detection area)

Replace if defective.
Refer to “TRANSMISSION” in chapter 5.

20 to 30 km / h.

B4

Defective neutral switch

Execute the diagnostic mode (code No. 21)
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.

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Summary of Contents for FZ6-ST

Page 1: ...FZ6 ST 5VX 28197 11 SUPPLEMENTARY SERVICE MANUAL LIT 11616 18 43 FZ6 STC ...

Page 2: ... Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 18 43 EAS00010 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FZ6 ST FZ6 STC For complete service information procedures it is necessary to use this Supple mentary Service Manual together with the following manual FZ6 SS FZ6 SSC SERVICE MANUAL LIT 11616 17 50 5VX ...

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

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

Page 5: ...ls to indicate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap based grease Molybdenum disulfide grease Symbols to in the expl...

Page 6: ...ORQUES 2 ENGINE TIGHTENING TORQUES 2 CHASSIS TIGHTENING TORQUES 2 CABLE ROUTING 3 CHASSIS SWINGARM AND DRIVE CHAIN 14 CHECKING THE DRIVE CHAIN 14 ENGINE ENGINE 16 INSTALLING THE ENGINE 16 CONNECTING RODS AND PISTONS 18 REMOVING THE CONNECTING RODS AND PISTONS 19 CHECKING THE BIG END BEARINGS 20 INSTALLING THE CONNECTING ROD AND PISTON 24 ...

Page 7: ...m 0 20 in Item Standard Limit Drive chain Model manufacturer 50V4 DAIDO Link quantity 118 Drive chain slack 45 55 mm 1 77 2 17 in Maximum 15 link section 239 3 mm 9 42 in Item Standard Limit Ignition system T C I unit model manufacturer F8T812 MITSUBISHI USA F8T813 MITSUBISHI CAL Starting circuit cut off relay Model manufacture G8R 30Y V3 OMRON Coil resistance 162 198 Ω GENERAL SPECIFICATIONS ENGI...

Page 8: ...rque Remarks Nm m kg ft lb Connecting rod caps Bolt M7 8 15 120 1 5 120 11 120 Item Thread size Tightening torque Remarks Nm m kg ft lb Pivot shaft and frame M18 125 12 5 90 Sidestand switch nut M5 4 0 4 2 9 Shift rod and shift arm bolt M6 10 1 0 7 2 Footrest bracket and footrest cover plate M5 7 0 7 5 1 TIGHTENING TORQUES ...

Page 9: ...ars Clamp the horn lead and main switch lead upper side only to the 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 Route the horn lead by the headmost side 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 fro...

Page 10: ...etween the band and terminals Clamp the brake hose to the 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 Pass the throttle cables through the wire guide Route the right handlebar switch lead by the out side of the wire guide CABLE ROUTING ...

Page 11: ...urn signal relay Radiator fan motor relay Dimmer relay Starting circuit cut off relay Clamp License plate light lead Rear turn signal light lead right Rear turn signal light lead left Speed sensor lead Sidestand switch lead Oil level switch lead A C magneto lead Throttle cable return side Throttle cable pull side Radiator fan motor lead Oil level gauge lead A C magneto lead Speed sensor lead CABLE...

Page 12: ...t make sure that the leads are not crossed Clamp the rear turn signal light lead and license plate light lead to the frame Hook the clamp to the bracket 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 Clamp the rear turn signal light lead and license plate light lead to the ...

Page 13: ... section To the headlight lead Point the tip of the clamp to the inner side of the vehicle body Make sure to pass the neutral switch lead through the hole of the flap Clamp the seat lock wire to the frame as shown in the illustration Secure the clamp to the weld of the cross member with the frame Position the binding section in front of the vehicle body and cut the tip to be between 1 and 5 mm 0 0...

Page 14: ...eservoir hose Lean angle cut off switch Fuse box Rear turn signal light lead right License plate light lead Rear turn signal light lead left Seat lock cable Rectifier regulator E C U Fuel tank drain hose Cover Starter relay lead Battery negative lead Battery negative lead coupler Clutch cable Connecter cover Cover 2 Spark plug lead Air cut off valve hose CABLE ROUTING ...

Page 15: ...sor lead Point the projected part of the tip to the inner side of the vehicle Pass the radiator hose coolant reservoir hose wire harness and starter motor lead in order through the lower side of the vehicle Set the 4 pin coupler in the connector cover after wiring it To the sidestand switch To the speed sensor To the A C magneto To the oil level switch To the tail brake light switch To the neutral...

Page 16: ...over Position of the clamp is forward of the cable stopper To the main switch Plate the adjuster of the clutch cable above the cover Route the starter relay lead outside of the main switch Press the battery negative lead into the space between the ribs of the frame After connecting the coupler of the connector cover position it inside Pass the spark plug leads 1 and 4 through the slit of the cover...

Page 17: ...tion Route the spark plug lead 3 under the air cut off valve hose Route the spark plug lead 2 behind the air cut off valve hose Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 Route the spark plug leads 2 and 3 behind the air cut off valve hose CABLE ROUTING ...

Page 18: ... knob of clip front side Fuel piping connector attachment directions fuel pump side 1 It is inserted until it makes a click sound the con nector and it checks that a connector does not fail out It takes care that a foreign substance does not enter into a seal portion Working gloves should not be used at the time of work It prevents that this portion falls out 2 The clamp is attached from the botto...

Page 19: ...ownward from back of the bolt Insert this portion securely Spittle is turned back Insert the clamp certainly It may open and close to direction of which All notches gear at the time of attachment Pass the coolant reservoir tank hose inside of the clamp Insert in certainly To the fuel tank drain tube Air opening There should be no slacking of the hose when it is routed CABLE ROUTING ...

Page 20: ...e chain front drive sprocket and rear drive sprocket as a set NOTE NOTE While measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaini...

Page 21: ...chain 4 Check O rings Damage Replace the drive chain drive chain rollers Damage wear Replace the drive chain drive chain side plates Damage wear Replace the drive chain Cracks Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate drive chain 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth ...

Page 22: ...bolt threads with lithium soap based grease 2 Install right front engine mounting bolt left front engine mounting bolts NOTE NOTE Do not fully tighten the bolts 3 Tighten self locking nut NOTE NOTE First tighten the lower self locking nut 4 Tighten left front engine mounting bolts 55 Nm 5 5 m kg 40 ft lb 55 Nm 5 5 m kg 40 ft lb ENGINE ...

Page 23: ...rm bolt NOTE NOTE Before installing make sure to align the punch mark of the shift shaft with the punch mark of the shift arm Align the bottom edge of the shift pedal with the mark on the frame to swingarm bracket 55 Nm 5 5 m kg 40 ft lb 10 Nm 1 0 m kg 7 2 ft lb ENGINE ...

Page 24: ... the order listed Lower crankcase Refer to CRANKCASE 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal procedure 15Nm 1 5 m kg 11ft lb 120 CONNECTING RODS AND PISTONS ...

Page 25: ...rive the piston pin out NOTE NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are deburred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 3 Remove top ring 2nd ring oil ring NOTE NOTE When removing a piston ring o...

Page 26: ...g into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE NOTE Align the projections on the big end bear ings with the notches in the connecting rod and connecting rod cap c Put a piece of Plastigauge on the crankshaft pin d Assemble the connecting rod halves NOTE NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lu...

Page 27: ...g rod i Tighten the connecting rod bolt while checking that the sections shown and are flush with each other by touching the surface Side machined face Thrusting faces 4 places at front and rear NOTE NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment j Loosen the connecting rod bolt remove the connecting rod and c...

Page 28: ... is flush with each other by touch ing the surface Side machined face WARNING When the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again If they are not flush with each other remove the connecting rod bolt and big end bearing and restart from step e In this case make sure to replace the con ...

Page 29: ... end bearings P1 P4 NOTE NOTE The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 respectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 5 ...

Page 30: ... face up 2 Install piston onto the respective connecting rod piston pin piston pin clip NOTE NOTE Apply engine oil onto the piston pin Make sure that the Y mark on the con necting rod faces left when the arrow mark on the piston is pointing up Refer to the illus tration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate piston piston rings cy...

Page 31: ...ner surface with the recommended lubricant 6 Install big end bearings connecting rod cap onto the connecting rod NOTE NOTE Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Make sure that the characters on both the connecting rod and connecting rod cap are aligned Recommended lubricant Engine oil CONNECTING RODS AND PISTONS ...

Page 32: ...ting faces 4 places at front and rear NOTE NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi tion 8 Install connecting rod assembly into th...

Page 33: ...lush with each other by touch ing the surface Side machined face WARNING When the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again If they are not flush with each other remove the connecting rod bolt and big end bearing and restart from step 7 In this case make sure to replace the con necti...

Page 34: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 35: ......

Page 36: ... by Yamaha Motor Corporation U S A First edition November 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 17 50 ...

Page 37: ...s policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual wh...

Page 38: ...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 39: ...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 40: ...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 ...

Page 41: ...OCK 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 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 10 ELECTRICAL SPECIFICATIONS 2 14 CONVERSION TABLE 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTE...

Page 42: ...E 3 11 ADJUSTING THE VALVE CLEARANCE 3 11 SYNCHRONIZING THE THROTTLE BODIES 3 17 ADJUSTING THE ENGINE IDLING SPEED 3 19 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 20 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 FILT...

Page 43: ...THE LEVERS AND PEDALS 3 57 LUBRICATING THE SIDESTAND 3 57 LUBRICATING THE CENTERSTAND 3 57 LUBRICATING THE REAR SUSPENSION 3 58 ELECTRICAL SYSTEM 3 59 CHECKING AND CHARGING THE BATTERY 3 59 CHECKING THE FUSES 3 65 REPLACING THE HEADLIGHT BULBS 3 67 ADJUSTING THE HEADLIGHT BEAMS 3 68 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS 4 1 REMOVING THE FRONT WHEEL 4 3 CHECKING THE FRONT WHEEL 4 3 CHECKING...

Page 44: ... BRAKE CALIPERS 4 40 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4 41 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4 43 FRONT FORK 4 45 FRONT FORK LEGS 4 45 REMOVING THE FRONT FORK LEGS 4 48 DISASSEMBLING THE FRONT FORK LEGS 4 48 CHECKING THE FRONT FORK LEGS 4 50 ASSEMBLING THE FRONT FORK LEGS 4 51 INSTALLING THE FRONT FORK LEGS 4 54 HANDLEBAR 4 55 REMOVING THE HANDLEBAR 4 56 CHECKING T...

Page 45: ...D TIMING CHAIN GUIDES 5 14 CHECKING THE TIMING CHAIN TENSIONER 5 14 INSTALLING THE CAMSHAFTS 5 15 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 20 CHECKING 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...

Page 46: ...51 CHECKING THE CLUTCH BOSS 5 51 CHECKING THE PRESSURE PLATE 5 51 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 52 INSTALLING THE CLUTCH 5 52 OIL PAN AND OIL PUMP 5 55 REMOVING THE OIL PAN 5 58 CHECKING THE OIL PUMP 5 58 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...

Page 47: ...E CRANKSHAFT JOURNAL BEARINGS 5 88 INSTALLING THE CRANKSHAFT 5 91 TRANSMISSION 5 92 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 92 REMOVING THE TRANSMISSION 5 98 CHECKING THE SHIFT FORKS 5 98 CHECKING THE SHIFT DRUM ASSEMBLY 5 99 CHECKING THE TRANSMISSION 5 99 INSTALLING THE TRANSMISSION 5 100 CHAPTER 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 4 OIL CO...

Page 48: ...E FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 29 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 30 AIR INDUCTION SYSTEM 7 32 AIR INJECTION 7 32 AIR CUT OFF VALVE 7 32 AIR INDUCTION SYSTEM DIAGRAMS 7 33 CHECKING THE AIR INDUCTION SYSTEM 7 34 CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 8 1 CHECKING SWITCH CONTINUITY 8 3 CHECKING THE SWITCHES 8 4 CHECKING THE BULBS AND BULB SOCKETS 8 5 ...

Page 49: ...CHECKING THE LIGHTING SYSTEM 8 31 SIGNALING SYSTEM 8 34 CIRCUIT DIAGRAM 8 34 TROUBLESHOOTING 8 36 CHECKING THE SIGNALING SYSTEM 8 36 COOLING SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 44 FUEL PUMP SYSTEM 8 47 CIRCUIT DIAGRAM 8 47 FUEL PUMP SYSTEM 8 48 TROUBLESHOOTING 8 49 CHECKING THE FUEL PUMP 8 51 SELF DIAGNOSIS 8 52 TROUBLESHOOTING 8 53 CHAPTER 9 TROUBLESHOOTING STARTING FAILURES 9 1 EN...

Page 50: ...IS 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 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 FAULTY LIGHTING OR SIGNALING SYSTEM 9 6 HEADLIGHT DOES 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...

Page 51: ...OTORCYCLE 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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ... 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 59: ...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 60: ...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 61: ...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...

Page 62: ... 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 USA except for CAL 208 kg 459 lb CAL 190 kg 419 lb USA except for CAL 189 kg 417 lb CAL SSS SSS ...

Page 63: ...eserve Reserve only 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 At 5_C 40_F or higher Yamalube 4 20W40 or SAE 20W40 type SE mo...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...Green 4 Yellow 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 sprin...

Page 70: ...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 at 2...

Page 71: ...avel 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 90 X 189 kg 198 X 417 lb High speed riding Min tire tread depth Tubeless 120 70 ZR17 M C 58W BT020F GG BRIDGESTONE D252F D...

Page 72: ...ess Max deflection Brake pad lining thickness 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...

Page 73: ...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 74: ...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 75: ...S 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 SSS SSS SSS Bat...

Page 76: ... 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 105 X 118 db 2 m 1 ...

Page 77: ...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 manufacture ...

Page 78: ...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 79: ... pump Bolt M6 2 12 1 2 8 7 Thermo sensor 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 M...

Page 80: ...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 81: ...2 20 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence ...

Page 82: ...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 Fornt frame and rear frame upper M10 41 4 1 30 Front frame and rear frame lower M10 41 4 1 30 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 ...

Page 83: ...22 Rear brake caliper bolt front and rear brake caliper 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...

Page 84: ... 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 85: ...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 86: ...2 25 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Oil cooler COOLING SYSTEM DIAGRAMS ...

Page 87: ...2 26 COOLING SYSTEM DIAGRAMS SPEC 1 Water pump 2 Oil cooler 3 Radiator ...

Page 88: ...2 27 COOLING SYSTEM DIAGRAMS SPEC 1 Oil cooler 2 Water pump ...

Page 89: ...2 28 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Thermostat ...

Page 90: ...2 29 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART ...

Page 91: ...2 30 LUBRICATION DIAGRAMS SPEC 1 Oil level switch 2 Oil cooler 3 Relief valve LUBRICATION DIAGRAMS ...

Page 92: ...2 31 LUBRICATION DIAGRAMS SPEC 1 Oil pump 2 Exhaust camshaft 3 Intake camshaft 4 Oil strainer ...

Page 93: ...2 32 LUBRICATION DIAGRAMS SPEC 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump ...

Page 94: ...2 33 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Oil pump 3 Relief valve ...

Page 95: ...2 34 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft ...

Page 96: ...2 35 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Drive axle ...

Page 97: ...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 98: ...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 99: ...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 100: ...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 101: ...cable pull 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 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 motor rela...

Page 102: ...the leads are not crossed K 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 L Clamp the rear turn signal lead and license plate light lead to the frame Cut the tip of the...

Page 103: ... the tip to be between 1 and 5 mm 0 04 and 0 20 in R To the rear turn signal light left S Pass the fuel tank drain hose through the clamp lo cated under the coolant reservoir tank T Route it behind the starter motor lead U 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 V To the headlight lead W Point ...

Page 104: ... 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 105: ...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 106: ... 3 under the air cut off valve hose AK 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 ...

Page 107: ...2 46 CABLE ROUTING SPEC AL Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 AM Route the spark plug leads 2 and 3 behind the air cut off valve hose ...

Page 108: ...be used at the time of work E It prevents that this portion falls out 2 The clamp is attached from the bottom after the work of 1 It checks being completely equipped with and section A B C 1 Fuel pump assembly 2 Fuel tank breather hose except for CAL 3 Fuel tank drain hose 4 Fuel hose 5 Clip 6 Clamp 7 Charge hose for CAL 8 Roll over valve for CAL A Air opening B Install the O ring with its lip poi...

Page 109: ...d close to direction of which All notches gear at the time of attachment G Pass the coolant reservoir tank hose inside of the clamp H Insert in certainly I To the fuel tank drain tube J Air opening K There should be no slacking of the hose when it is routed except for CAL 1 Coolant breather hose 2 Coolant reservoir tank 3 Coolant reservoir tank hose 4 Clamp 5 Fuel tank drain hose CABLE ROUTING SPE...

Page 110: ...ob of the clip upward The application of water is possible at the time of attachment G Pass the balance hose under the canister hose H Insert this portion securely I Spittle is turned back J Insert to the back but the tip of the nipple should not come out from the hose for CAL 1 Clip 2 Roll over valve 3 Canister hoes 4 Balance hose 5 Coolant reservoir tank 6 Coolant reservoir tank hose 7 Coolant b...

Page 111: ...k drain hose inside of the clamp N Point the knob of clamp downward O Point the knob of clamp upward P Insert in certainly Q To the fuel tank drain tube R Point the paint marking both white front side The application of water is possible at the time of attach ment S Clamp the fuel tank drain hose then the paint mark of the central part is united T Air opening CABLE ROUTING SPEC ...

Page 112: ...page 3 36 S Check for leakage S Tighten if necessary S Replace gasket s if necessary Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 7 Evaporative emission control system For California only S Check control system for damage S Replace if necessary Ǹ Ǹ 8 Air induction system See page 7 32 S Check the air cut off valve reed valve and hose for damage S Replace any damaged parts if necessary Ǹ Ǹ Since these items require special tools d...

Page 113: ...17 Front fork See page 3 53 S Check operation and for oil leakage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 18 Shock absorber assembly See page 3 54 4 65 S Check operation and for oil leakage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 19 Rear suspension link pivots See page 4 70 S Check operation S Correct if necessary Ǹ Ǹ 20 Engine oil See page 3 27 28 S Change warm engine before draining Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 21 Engine oil ...

Page 114: ...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 115: ...r coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose except for CAL Canister hose for CAL 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 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb NOTE EAS00040 FUEL TANK ...

Page 116: ...NK CHK ADJ Order Job Part Q ty Remarks 8 Roll over valve for CAL 1 For installation reverse the removal procedure Refer to the CABLE ROUTING for how to attach a hose 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb ...

Page 117: ...in ing in it STo remove the fuel hose from the fuel injection pipe slide the cover a on the end of the hose in the direction of the arrow shown and then re move the hose SBefore 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...

Page 118: ...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 Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection hose slide the cover a on the end of the hose in...

Page 119: ...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 120: ...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 121: ...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 122: ... 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 123: ...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 124: ...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 125: ...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 126: ... 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 127: ... 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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...le cable free play is decreased c Tighten the locknut 4 Install Sbattery assembly Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Sair filter case Refer to AIR FILTER CASE Sfuel tank Refer to FUEL TANK 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 l...

Page 133: ...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 134: ...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 135: ...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 136: ...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 137: ...the engine warm it up for several min utes and then turn it off 3 Check Sengine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Recommended oil AT 5_C 40_F or higher A Yamalube 4 20W40 or SAE 20W40 type SE motor oil AT 15_C 60_F or lower B Yamalube 4 10W30 or SAE 10W30...

Page 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ... 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 154: ...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 155: ... 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 156: ...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 157: ...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 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...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 positions Minimum 1 Standard 3 Maximum 7 EAS00162 CHECKING THE TIR...

Page 165: ...ght with oil and a full fuel tank 207 kg 456 lb 208 kg 459 lb for CAL Maximum load 190 kg 419 lb 189 kg 417 lb for CAL 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 90 kg X 189 kg 198 X 417 lb for CAL maximum load 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi Hig...

Page 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ... 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 177: ...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 178: ...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 179: ... 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 180: ...Collar left and right Front wheel Front brake disc left and right 2 2 1 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 ftSl...

Page 181: ... 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 182: ... 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 183: ...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 184: ...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 185: ...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 186: ...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 187: ... 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 188: ...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 189: ...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 190: ... 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 191: ...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 192: ... 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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...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 198: ...ctor 1 Sside reflector bracket left side only 2 Sbrake hose holder 3 Sbrake caliper 4 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 Alway...

Page 199: ...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 200: ... 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 201: ...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 202: ...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 203: ...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 204: ... 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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...r 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 4 Nm 0 4 mSkg 2 9 ftSlb EAS00613 FRONT BRAKE CALIPERS ...

Page 214: ...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 215: ...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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ... 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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...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 236: ... 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 237: ...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 238: ... Main switch coupler Steering stem nut Washer Upper bracket Horn stay Lock washer 2 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 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 BRACKET ...

Page 239: ...er 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 240: ... 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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...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 246: ... 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 247: ... 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 248: ...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 249: ... 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 250: ... 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 251: ...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 252: ...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 253: ...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 254: ...over 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 255: ...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 256: ...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 257: ...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 258: ... 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 259: ...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 260: ...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 261: ...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 262: ...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 263: ...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 264: ...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 265: ... 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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ...5 18 CAMSHAFTS ENG 10 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 ...

Page 272: ...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 273: ...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 274: ...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 275: ...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 276: ...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 277: ...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 278: ...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 279: ...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 280: ... 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 281: ...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 282: ...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 283: ...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 284: ...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 285: ...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 286: ...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 287: ...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 288: ...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 289: ...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 290: ...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 291: ...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 292: ... 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 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...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 299: ...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 300: ...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 301: ... 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 302: ...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 303: ...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 304: ...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 305: ...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 2 Bend the lock washer tab along a flat side of the nut 3 Lubricate Sfriction plates Sclutch plates with the recommen...

Page 306: ...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 5 Install Spressure plate 1 Align the punch mark b in the pressure plate with the punch mark a in the clutch boss 6 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 307: ...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 9 Adjust Sclutch cable free play Refer to ADJUSTING THE CLUTC...

Page 308: ...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 309: ...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 310: ... 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 311: ...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 312: ...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 313: ...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 314: ...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 315: ...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 316: ...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 317: ...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 318: ...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 319: ...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 320: ...ng 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 120_ 15 Nm 1 5 mSkg 11 ftSlb 150_ CONNECTING RODS AND PISTONS ENG EAS00252 CONNECTING RODS AND PISTONS ...

Page 321: ...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 322: ...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 323: ... 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 324: ... 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 325: ...bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 16 002 X 16 013 mm 0 6300 X 0 6304 in Limit 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 0 000...

Page 326: ...lean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod 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...

Page 327: ...further 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 and nut 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...

Page 328: ...ods are used to determine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the 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 ...

Page 329: ...an the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod 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 h...

Page 330: ...nnecting rod and connecting rod cap once using a single unit of the connecting rod i Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out ...

Page 331: ...ther to reach the specified angle 120_ p After the installation check that the section show a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bo...

Page 332: ...t big end bearings 2 Select Sbig end bearings P1 X P4 SThe numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re spectively then the bearing size for P1 is ...

Page 333: ... the manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y mark a on the connect ing rod faces left when the arrow mark b on the piston is pointing up Refer to the illustra tion SReinstall each piston into its original cylinder numbering order starting from ...

Page 334: ...e big end bearings with the notches in the connecting rods and connecting rod caps SBe sure to reinstall each big end bearing in its original place SWhile compressing the piston rings with one hand install the 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 character...

Page 335: ...n the nut further to reach the specified angle 150_ When the nut is tightened more than the spe cified angle do not loosen the nuts and then retighten it Replace the bolt and nut 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...

Page 336: ... manufacturer s marks or numbers a face up 2 Install Spiston 1 onto the respective connecting rod 2 Spiston pin 3 Spiston pin clip New 4 SApply engine oil onto the piston pin SMake sure that the Y mark a on the connect ing rod faces left when the arrow mark b on the piston is pointing up Refer to the illustra tion SReinstall each piston into its original cylinder numbering order starting from the ...

Page 337: ... end bearings Sconnecting rod big end inner surface with the recommended lubricant Recommended lubricant Engine oil 6 Install Sbig end bearings Sconnecting rod cap onto the connecting rod SAlign the projections on the big end bearings with the notches in the connecting rods and connecting rod caps SMake sure that the characters a on both the connecting rod and connecting rod cap are aligned ...

Page 338: ...sh with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in th...

Page 339: ...ied angle 120_ e After the installation check that the section shown a is flush with each other by touching the surface SSide machined face a SWhen the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bolt and big end bear ing...

Page 340: ...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 341: ...nkshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 034 X 0 058 mm 0 0013 X 0 0023 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 342: ...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 343: ...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 344: ...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 345: ... 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 346: ...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 347: ... 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 348: ...5 95 Order Job Part Q ty Remarks Bearing housing Bearing 1 1 For installation reverse the removal procedure 15 16 TRANSMISSION ENG ...

Page 349: ...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 350: ...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 351: ...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 352: ...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 353: ...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 354: ... 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 355: ...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 356: ...6 2 6 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 357: ...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 358: ...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 359: ...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 360: ...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 361: ...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 362: ...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 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ... 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 370: ...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 371: ... 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 372: ...Intake air pressure sensor 16 Lean angle cut off switch 17 Crankshaft position sensor 18 Intake air temperature sensor 19 Coolant temperature sensor 20 ECU 21 Cylinder 1 injector 22 Cylinder 2 injector 23 Cylinder 3 injector 24 Cylinder 4 injector 26 Speed sensor 27 Ignition coil 1 and 4 28 Ignition coil 2 and 3 29 Spark plug 32 Engine trouble warning light 34 Multi function meter 40 Engine stop s...

Page 373: ...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 374: ...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 375: ...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 376: ...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 377: ...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 378: ...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 379: ...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 380: ...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 381: ...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 382: ...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 383: ...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 384: ... 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 385: ... 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 386: ...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 387: ...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 388: ... 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 defective...

Page 389: ... 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 390: ...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 391: ...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 392: ...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 393: ...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 394: ...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 395: ...rottle body joint clamp screw Throttle bodies Throttle cable Throttle body joint Heat protector 2 1 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 Disconnec...

Page 396: ...7 26 Order Job Part Q ty Remarks 9 Plunger control unit hose 1 Disconnect For installation reverse the removal procedure THROTTLE BODIES FI ...

Page 397: ...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 398: ...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 399: ...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 400: ... 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 401: ... 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 402: ...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 403: ...7 33 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 404: ...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 405: ...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 406: ...l switch 10 Radiator fan motor 11 Horn 12 Ignition coil 1 Main switch 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 407: ...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 408: ...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 409: ...and 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 410: ... 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 411: ...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 412: ...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 413: ...destand switch 12 Neutral switch 16 Lean angle cut off switch 17 Crankshaft position sensor 20 ECU 27 Ignition coil 1 and 4 28 ignition coil 2 and 3 29 Spark plug 40 Engine stop switch 47 Fuse ignition 54 Clutch switch IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 414: ...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 415: ...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 416: ...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 417: ...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 418: ...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 419: ...8 Starter motor 9 Battery 10 Starting circuit cut off relay 11 Sidestand switch 12 Neutral switch 40 Engine stop switch 41 Start switch 47 Fuse ignition 54 Clutch switch ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 420: ... 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 421: ...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 422: ...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 423: ...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 424: ...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 425: ...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 426: ...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 427: ... 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 428: ... 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 429: ...8 24 2 A C magneto 3 Rectifier regulator 6 Fuse main 9 Battery CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 430: ...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 431: ...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 432: ...8 27 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 433: ...gh beam indicator light 46 Fuse headlight 47 Fuse ignition 48 Fuse tail 51 License plate light 52 Tail brake light 55 Dimmer switch 60 Dimmer relay 61 Headlight high beam 62 Headlight low beam 65 Front turn signal position light right 66 Front turn signal position light left ...

Page 434: ... tail ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main tail 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 following fail to light headlight high beam indicator light taillight licence light or mete...

Page 435: ...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 6 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 436: ... 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 437: ...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 438: ...n light fails to come on YES NO 1 Turn signal position light and socket SCheck the turn signal position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the turn signal position light bulb and socket OK Replace the turn sig nal position light bulb socket or both YES NO 2 Voltage SConnect the pocket tester DC 20 V to the turn signal position light coupler wire ...

Page 439: ...8 34 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 440: ...unction meter 36 Turn signal indicator light 37 Oil level switch 39 Front brake light switch 45 Fuse signal 47 Fuse ignition 48 Fuse tail 49 Turn signal relay 50 Rear brake light switch 52 Tail brake light 56 Hazard switch 57 Turn signal switch 58 Horn switch 59 Horn 63 Rear turn signal light right 64 Rear turn signal light left 65 Front turn signal position light right 66 Front turn signal positi...

Page 441: ...GHTING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Backup main ignition signal and tail fuses SCheck the backup main ignition signal and tail fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the backup main ignition signal and tail 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 442: ...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 443: ...d 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 wir...

Page 444: ...r continu 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 ch...

Page 445: ...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 446: ...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 447: ...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 448: ...tch 6 Fuse main 9 Battery 19 Coolant temperature sensor 20 ECU 42 Fuse radiator fan motor 43 Radiator fan motor relay 44 Radiator fan motor 47 Fuse ignition COOLING SYSTEM ELEC EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 449: ...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 450: ...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 451: ... 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 452: ...in switch 5 Fuse fuel injection 6 Fuse main 9 Battery 10 Starting circuit cut off relay 13 Fuel pump 20 ECU 40 Engine stop switch 47 Fuse ignition FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 453: ... 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 454: ...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 455: ... 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 456: ...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 457: ...the 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...

Page 458: ...on SIs the fuel pump thermistor OK YES Replace the fuel pump Replace the multi function meter NOTE 13 Fuel pump 34 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 459: ...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 34 Multi function meter 37 Oil level switch 2 Oil level switch CIRCUIT DIAGRAM ...

Page 460: ...f 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 valv...

Page 461: ...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 462: ...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 463: ...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 464: ...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 465: ...FZ6 SS FZ6 SSC WIRING DIAGRAM ...

Page 466: ... Coolant temperature sensor 20 ECU 21 Cylinder 1 injector 22 Cylinder 2 injector 23 Cylinder 3 injector 24 Cylinder 4 injector 25 Air cut off valve 26 Speed sensor 27 Ignition coil 1 and 4 28 Ignition coil 2 and 3 29 Spark plug 30 Meter assembly 31 Oil level warning light 32 Engine trouble warning light 33 Neutral indicator light 34 Multi function meter 35 High beam indicator light 36 Turn signal ...

Page 467: ...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 468: ...G B B Y Br R Y G Y B R Y Br B L G Y R W Dg Y L B Br W Ch B R G B B Y Br B L W Y W Y B B Br Y Br G Y R R L W L W R B B L B L B B Y B Y B B L G B B R B R R L W L R B L W L W R Lg B Y Sb B R L G R W L Y L W B R B W Ch B B Ch B R Br Dg B FREE PUSH OFF RUN Ch Dg B G W R W B R L Dg B W Y L B L Br B R W Sb Sb Y L Y R R L R L Gy B Gy B L Br L L B ON OFF R B W L B R B R B W L Y B L R L L Y L Y R W Gy Gy R ...

Page 469: ......

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