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CABLE ROUTING

2-64

1.  Synchronizing hose #1
2.  Synchronizing hose #2
3.  Synchronizing hose #3
4.  Synchronizing hose #4
5.  Fast idle plunger coolant hose
6.  Throttle position sensor
7.  Fuel injector #4
8.  Intake air pressure sensor
9.  Fuel injector #3
10. Fuel injector #2
11. Fuel injector #1
12. Fast idle plunger hose (fast idle plunger-throttle

body #4)

13. Fast idle plunger
14. Fast idle plunger hose (fast idle plunger-throttle

body #1)

15. Fast idle plunger hose (fast idle plunger-throttle

body #2)

16. Fast idle plunger hose (fast idle plunger-throttle

body #3)

17. Negative pressure hose (throttle body-intake air

pressure sensor)

A. Red paint mark

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Summary of Contents for FZ6RC

Page 1: ...SERVICE MANUAL FZ6RY C 2009 36P 28197 10 LIT 11616 22 77 ...

Page 2: ......

Page 3: ...Yamaha Motor Corporation U S A First edition December 2008 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 22 77 ...

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

Page 5: ...Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disassem bly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction c...

Page 6: ...erviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Engine oil Gear oil Molybdenum disulfide oil Brake fluid Wheel bearing grease Lithium soap based grease Molybdenum disulfide grease Silicone grease Apply locking agent LOCTITE Replace the part with a new one SYMBOL DEFINITION SYMBOL DEFINITION ...

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

Page 8: ......

Page 9: ...EM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 REMOVING THE QUICK FASTENER 1 10 INSTALLING THE QUICK FASTENER 1 11 SPECIAL TOOLS 1 12 ...

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

Page 11: ...mes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of a conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to ...

Page 12: ...n the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU engine control unit Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor and coolant temperature sensor enable the ECU engine control unit to determine the injection duration The injection ...

Page 13: ... the SELECT button for at least one second Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit NOTICE ECA20S1006 Do not operate the engine in the tachometer red zone Red ...

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

Page 15: ...those circuits the engine trouble warning light will come on and the display will indicate an error code If the display indicates any error codes note the code number and then check the vehicle NOTICE ECA20S1008 If the display indicates an error code the ve hicle should be checked as soon as possible in order to avoid engine damage 1 Error code display 1 ...

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

Page 17: ...rease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 18: ...dirty NOTICE ECA20S1003 When you disconnect electronic parts from the wire harness always turn off the main switch If you disconnect above condition it may damage the electronic parts TIP When you check the electric system of a motor cycle check the battery voltage before Mini mum 11V is requested to check each component function Check the leads couplers and connectors for stains rust moisture etc...

Page 19: ...no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores TIP When you check the voltage or electrical conti nuity insert the measuring probe from back side as you can insert from back side EAS21840 REMOVING THE QUICK FASTENER TIP To remove the quick fastener push its center with a screwdriver the...

Page 20: ...NG THE QUICK FASTENER TIP To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin is flush with the fastener s head ...

Page 21: ...er to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 10 8 77 8 85 8 91 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 6 Valve lapper 90890 04101 Valve lapping tool YM A89...

Page 22: ...ester YU 33223 5 18 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 18 4 53 Damper rod holder 90890 01460 4 46 4 48 T handle 90890 01326 YM 01326 4 46 4 48 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 48 4 49 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 23: ...4019 5 21 5 26 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 21 5 26 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 22 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 5 22 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 22 Tool name Tool No Illustration Reference pages ...

Page 24: ...ller attachment 90890 04089 Crankshaft protector YM 33282 5 30 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 32 5 34 5 61 6 12 Camshaft wrench 90890 04143 YM 04143 5 34 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 38 7 10 8 78 8 79 8 83 8 84 8 86 8 87 8 88 8 89 8 90 8 91 8 93 Tool name Tool No Illustration Reference pages ...

Page 25: ...der 90890 04086 YM 91042 5 50 5 54 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 66 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Tool name Tool No Illustration Reference pages YU 01304 YU 24460 01 ...

Page 26: ... pump seal installer YM 33221 A 6 12 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 12 Fuel injector pressure adapter 90890 03210 YU 03210 7 7 Fuel pressure adapter 90890 03176 YM 03176 7 9 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 85 Tool name Tool No Illustration Reference pages YU 33984 ...

Page 27: ...HTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 39 CABLE ROUTING 2 41 ...

Page 28: ...Overall length 2120 mm 83 5 in Overall width 770 mm 30 3 in Overall height 1185 mm 46 7 in Seat height 785 mm 30 9 in Wheelbase 1440 mm 56 7 in Ground clearance 140 mm 5 51 in Minimum turning radius 2800 mm 110 2 in Weight With oil and fuel FZ6RY 212 0 kg 467 lb FZ6RYC 213 0 kg 470 lb Maximum load FZ6RY 188 kg 414 lb FZ6RYC 187 kg 412 lb ...

Page 29: ...9 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 50 L 2 64 US qt 2 20 Imp qt With oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 090 0 150 mm 0 0035 0 0059 in Limit 0 2...

Page 30: ...t Camshaft cap inside diameter 23 008 23 029 mm 0 9058 0 9067 in Camshaft journal diameter 22 967 22 980 mm 0 9042 0 9047 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 080 mm 0 0032 in Camshaft lobe dimensions Intake A 31 850 31 950 mm 1 2539 1 2579 in Limit 31 800 mm 1 2520 in Intake B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 900 mm 0 9803 in Exhaust A 31...

Page 31: ...n thickness D intake 0 60 0 80 mm 0 0236 0 0315 in Limit 0 5 mm 0 02 in Valve margin thickness D exhaust 0 60 0 80 mm 0 0236 0 0315 in Limit 0 5 mm 0 02 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 ...

Page 32: ...3 50 15 54 kgf 29 76 34 26 lbf Installed compression spring force exhaust 132 40 152 40 N 13 50 15 54 kgf 29 76 34 26 lbf Spring tilt intake 2 5 1 7 mm Spring tilt exhaust 2 5 1 7 mm Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 65 500 65 510 mm 2 5787 2 5791 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder cle...

Page 33: ...cting rod Oil clearance 0 038 0 062 mm 0 0015 0 0024 in Limit 0 08 mm 0 0032 in Bearing color code 1 Yellow Blue 2 Yellow Black 3 Yellow Brown 4 Yellow Green Crankshaft Width A 51 90 52 50 mm 2 04 2 07 in Width B 268 80 270 00 mm 10 58 10 63 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Small end free play F 0 32 0 50 mm 0 01 0 02 in Journal oil clea...

Page 34: ... reduction system Chain drive Secondary reduction ratio 46 16 2 875 Operation Left foot operation Gear ratio 1st 37 13 2 846 2nd 37 19 1 947 3rd 28 18 1 556 4th 32 24 1 333 5th 25 21 1 190 6th 26 24 1 083 Main axle runout limit 0 02 mm 0 0008 in Drive axle runout limit 0 02 mm 0 0008 in Shifting mechanism Shift mechanism type Shift drum Shift fork guide bar bending limit 0 050 mm 0 0020 in Shift f...

Page 35: ...by tachometer Idling condition Engine idling speed 1250 1350 r min CO 4 5 5 5 Intake vacuum 32 0 kPa 238 mmHg 9 37 inHg Water temperature 95 0 105 0 C 203 00 221 00 F Oil temperature 75 0 85 0 C 167 00 185 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 36: ...turer model DUNLOP ROADSMART Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 160 60 ZR17M C 69W Manufacturer model BRIDGESTONE BT021 Manufacturer model DUNLOP ROADSMART Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Loading condition FZ6RY 90 188 kg 198 414 lb...

Page 37: ...ng free length 365 1 mm 14 37 in Collar length 145 0 mm 5 71 in Installed length 358 1 mm 14 10 in Spring rate K1 7 40 N mm 0 75 kgf mm 42 25 lb in Spring rate K2 11 80 N mm 1 20 kgf mm 67 38 lb in Spring stroke K1 0 0 70 0 mm 0 00 2 76 in Spring stroke K2 70 0 130 0 mm 2 76 5 12 in Inner tube outer diameter 41 0 mm 1 61 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Quant...

Page 38: ...CHASSIS SPECIFICATIONS 2 11 Drive chain slack 45 0 55 0 mm 1 77 2 17 in 15 link length limit 239 3 mm 9 42 in ...

Page 39: ...ard output 14 0 V 330 W 5000 r min Stator coil resistance 0 240 0 360 Ω W W Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage 14 1 14 9 V Rectifier capacity 35 0 A Battery Model GT12B 4 Voltage capacity 12 V 10 0 Ah Specific gravity 1 330 Manufacturer GS YUASA Ten hour rate amperage 1 00 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headli...

Page 40: ...ane Quantity 1 pcs Maximum amperage 3 0 A Coil resistance 1 07 1 11 Ω Turn signal relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 19 0 21 0 Ω Sender unit resistance empty 139 0 141 0 Ω Starting circuit cut off relay Coil resistance 162 0 198 0 Ω Headlight relay Coil resistance 86 40 105 60 Ω Thermo unit Resistance at 80 C 290 0 354 0 ...

Page 41: ...m 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Spark plugs M10 4 13 Nm 1 3 m kgf 9 4 ft lbf Cylinder head stud bolt M8 8 15 Nm 1 5 m kgf 10 ft lbf Cylinder head plug M20 3 42 Nm 4 2 m kgf 30 ft lbf Cylinder head bolt M10 10 See TIP Cylinder head bolt M6 2 12 Nm 1 2 m kgf 8 7 ...

Page 42: ...on bolt M20 1 70 Nm 7 0 m kgf 51 ft lbf Oil filter M20 1 17 Nm 1 7 m kgf 12 ft lbf Apply grease O Oil pump chain guide bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Oil pipe bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Intake air temperature sensor M5 1 2 5 Nm 0 3 m kgf 1 8 ft lbf Throttle body joint bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Air filter case cover M5 9 2 5 Nm 0 3 m kgf 1 8 ft lbf Air filter case M6 1 7 ...

Page 43: ...m 1 0 m kgf 7 2 ft lbf Push lever assembly shaft stopper M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Push lever assembly M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Pickup coil rotor cover bolt M6 7 10 Nm 1 0 m kgf 7 2 ft lbf Timing mark accessing bolt M8 1 15 Nm 1 5 m kgf 11 ft lbf Breather plate screw M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Stator coil bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Stator coil lead clamp screw M6 1 10 N...

Page 44: ...Clutch pressure plate screw M6 6 8 Nm 0 8 m kgf 5 8 ft lbf Clutch boss nut M20 1 95 Nm 9 5 m kgf 68 ft lbf Stake the nut on slot of shaft Push rod 2 lock nut M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Drive sprocket nut M20 1 85 Nm 8 5 m kgf 61 ft lbf Stake the nut on slot of shaft Transmission bearing housing screw M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Shift fork guide bar retainer bolt M6 2 10 Nm 1 0 m kgf 7 2 ft...

Page 45: ... 7 5 4 6 8 2 10 5 7 3 9 1 13 21 16 19 20 27 17 11 12 18 15 14 26 24 22 23 25 Item Threa d size Q ty Tightening torque Remarks Upper bracket pinch bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Grip end M16 2 26 Nm 2 6 m kgf 18 ft lbf Left handlebar switch screw M5 2 4 Nm 0 4 m kgf 2 9 ft lbf Right handlebar switch screw M5 3 4 Nm 0 4 m kgf 2 9 ft lbf ...

Page 46: ... Nm 5 5 m kgf 40 ft lbf See TIP Engine mount bolts right of front side M10 2 55 Nm 5 5 m kgf 40 ft lbf See TIP Engine mount self locking nut upper M10 1 55 Nm 5 5 m kgf 40 ft lbf See TIP Engine mount self locking nut lower M10 1 55 Nm 5 5 m kgf 40 ft lbf See TIP Throttle cable adjust nut M6 1 4 Nm 0 4 m kgf 2 9 ft lbf Clutch cable locknut M8 1 7 Nm 0 7 m kgf 5 0 ft lbf Pivot shaft nut M14 1 110 Nm...

Page 47: ...eed screw M7 2 6 Nm 0 6 m kgf 4 3 ft lbf Rear brake caliper bleed screw M7 1 5 Nm 0 5 m kgf 3 6 ft lbf Rear wheel axle nut M16 1 90 Nm 9 0 m kgf 64 ft lbf Rear brake disc and rear wheel M8 5 20 Nm 2 0 m kgf 14 ft lbf Rear brake caliper bolt front and rear brake caliper bracket M12 1 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bolt rear and rear brake caliper bracket M8 1 22 Nm 2 2 m kgf 16 ft lbf...

Page 48: ...f 6 5 ft lbf Footrest cover screw M5 4 4 Nm 0 4 m kgf 2 9 ft lbf Passenger footrest cover screw M5 2 2 4 Nm 0 4 m kgf 2 9 ft lbf Rear side reflector nut M5 2 2 Nm 0 2 m kgf 1 4 ft lbf Rear side reflector stay nut M4 4 3 Nm 0 3 m kgf 2 2 ft lbf Rear reflector nut M5 1 2 Nm 0 2 m kgf 1 4 ft lbf License plate bracket nut M6 2 4 Nm 0 4 m kgf 2 9 ft lbf Rear fender screw M5 4 2 5 Nm 0 3 m kgf 1 8 ft lb...

Page 49: ... intake and exhaust Valve stem ends intake and exhaust Valve lifter surface Piston cooler O ring or Oil pump rotors inner and outer Oil strainer or Clutch push rod Starter clutch assembly inner surface Idler gear Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Push lever axle and cover 2 Shift fork pin Cylinder head...

Page 50: ...ht and left Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand 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 sh...

Page 51: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 Sidestand bracket and link mating surface Lubrication point Lubricant LS ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 13 12 11 10 10 10 10 9 14 14 5 6 7 8 3 2 1 4 14 14 15 ...

Page 53: ...AGRAMS 2 26 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil filter 5 Oil cooler 6 Main axle 7 Oil pipe 8 Drive axle 9 Main gallery 10 Oil nozzle 11 Timing chain tensioner 12 Intake camshaft 13 Exhaust camshaft 14 Big end 15 Crankshaft ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS 1 5 3 2 4 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil level switch 2 Oil cooler 3 Relief valve 4 Ventilation chamber cover 5 Oil delivery pipe ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 3 7 8 2 1 4 6 5 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil pump 2 Exhaust camshaft 3 Intake camshaft 4 Oil strainer 5 Oil pipe 6 Oil delivery pipe 7 Timing chain tensioner 8 Oil check bolt ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 3 6 5 1 2 4 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump 5 Oil pipe 6 Oil filter ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2 4 5 3 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Oil pump 3 Relief valve 4 Oil pipe 5 Oil delivery pipe ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 3 2 5 4 1 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil nozzle ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 2 3 1 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Drive axle 3 Oil pipe ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 39 EAS20420 COOLING SYSTEM DIAGRAMS 1 1 2 2 3 5 6 4 4 7 ...

Page 67: ...COOLING SYSTEM DIAGRAMS 2 40 1 Radiator 2 Oil cooler 3 Water pump 4 Coolant reservoir 5 Fast idle plunger 6 Water pump breather hose 7 Water jacket joint ...

Page 68: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING ...

Page 69: ...leads at the white tape position Direct the end of clamp down and outward No need to cut off its end B Clamp the clutch cable C Clamp the throttle cables D Pass the wire harness above the bracket mounted at the rear side of the gusset E Pass the AC magneto lead under the clutch cable F Pass the clutch cable under the nut projection G Pass the clutch cable outside the radiator inlet hose ...

Page 70: ...CABLE ROUTING 2 43 ...

Page 71: ... tank E Insert the wire harness inside of the frame from behind the battery F Clamp the seat lock cable to the inside of frame in this area Direct the end of clamp out and upward No need to cut off its end G Take care not pinch the wire harness between bat tery and frame on the battery installation H Clamp the sidestand switch lead and oil level switch lead I The leads may be crossed J Pass the si...

Page 72: ...CABLE ROUTING 2 45 ...

Page 73: ... cap 1 A There is no order in overlapping the wire harness in this area B The either positive and negative ignition coil con nectors can be connected to the each terminal C To air cut off valve D Clamp the wire harness Direct the end of clamp in and downward No need to cut off its end E Place the right handlebar switch lead coupler and the radiator fan motor lead coupler underneath of the air cut ...

Page 74: ...CABLE ROUTING 2 47 ...

Page 75: ...C magneto C To oil level switch D To sidestand switch E To ground lead F To neutral switch G Clamp the wire harness H Insert the wire harness into the plate nut I Clamp the wire harness and starter motor lead Direct the end of clamp out and downwards No need to cut off its end J To fuel pump K To rear brake light switch L To speed sensor M To sub wire harness N Install the terminal to touch the pr...

Page 76: ...CABLE ROUTING 2 49 ...

Page 77: ...sert the alarm coupler under the wire harness B Pass the wire harness through the rear fender notch C Clamp the radiator fan motor relay lead relay unit lead and tail lead wire harness They may be clamped in any direction D Clamp the turn signal relay lead relay unit lead and seat lock cable They may be clamped in any direc tion E Pass the wire harness and seat lock cable through the rear fender n...

Page 78: ...CABLE ROUTING 2 51 ...

Page 79: ...side of the motorcycle B Insert it securely until it reaches its end position C Secure for 3 or more notches The pawl must be directed toward the front of the vehicle D Secure for 3 or more notches The pawl must be directed toward the rear of the vehicle E Install the brake pipe to touch the projection on the brake caliper ...

Page 80: ...CABLE ROUTING 2 53 ...

Page 81: ...ifornia only 13 Canister holder California only 14 Fuel tank breather hose canister to atmosphere California only A Clamp it securely The pawl must be directed toward the rear of the vehicle B Install the terminal against the bracket with crimp barrel side facing outwards C Install the brake pipe to touch the projection on the brake caliper D For California only E Pass the fuel tank breather hose ...

Page 82: ...CABLE ROUTING 2 55 ...

Page 83: ...d 6 Cable guide A Pass the horn lead front of the inner tube and clamp it on Direct the end of clamp toward front side of the vehi cle with its end pointing outside No need to cut off its end B 40 60 mm C The terminal must direct toward the out of the vehi cle D To headlight E Pass the throttle cable above the cable guide ...

Page 84: ...CABLE ROUTING 2 57 ...

Page 85: ... left Clamp the other leads at the white tape position Direct the end of clamp down and outward No need to cut off its end D Install the connector cover where underneath of the air cut off valve and front of the air filter with its opening facing on the right E Pass the coolant reservoir hose outside the fast idle plunger outlet hose and water pump breather hose outer side F Pass the fast idle plu...

Page 86: ...CABLE ROUTING 2 59 ...

Page 87: ...attery B Clamp the wire harness The opening must be directed upward C To fuel tank D The paint mark of both the fuel tank breather hose and the fuel tank drain hose must be positioned under the clamp E Clamp the fuel tank breather hose and fuel tank drain hose F Take care not pinch the rear brake light switch lead between the reservoir hose and master cylinder G The terminal of the neutral switch ...

Page 88: ...CABLE ROUTING 2 61 ...

Page 89: ...e California only 13 Fuel tank breather hose rollover valve to canister California only A Release to atmospheric pressure B Make sure that the connector is connected securely C The protrusion of the fuel pump must be aligned with the fuel tank mark D Direct the clip end toward front of the vehicle E For California only F Direct the clip end to ward top side of the vehicle G To canister H Position ...

Page 90: ...CABLE ROUTING 2 63 ...

Page 91: ...re sensor 9 Fuel injector 3 10 Fuel injector 2 11 Fuel injector 1 12 Fast idle plunger hose fast idle plunger throttle body 4 13 Fast idle plunger 14 Fast idle plunger hose fast idle plunger throttle body 1 15 Fast idle plunger hose fast idle plunger throttle body 2 16 Fast idle plunger hose fast idle plunger throttle body 3 17 Negative pressure hose throttle body intake air pressure sensor A Red ...

Page 92: ...CABLE ROUTING 2 65 ...

Page 93: ...re sensor 10 Fuel injector 3 11 Fuel injector 2 12 Fuel injector 1 13 Fast idle plunger hose fast idle plunger throttle body 4 14 Fast idle plunger 15 Fast idle plunger hose fast idle plunger throttle body 1 16 Fast idle plunger hose fast idle plunger throttle body 2 17 Fast idle plunger hose fast idle plunger throttle body 3 18 Negative pressure hose throttle body intake air pressure sensor A Red...

Page 94: ...CABLE ROUTING 2 67 ...

Page 95: ...r 10 Synchronizing hose 4 11 Synchronizing hose 3 A Secure the intake air pressure sensor lead throttle position sensor lead and synchronizing hoses 3 and 4 using clamp The top end of the clamp must be positioned close to throttle body 3 B Pass the synchronizing hoses 3 and 4 between the intake air pressure sensor lead and the throttle position sensor lead C Red paint mark D Secure the fast idle p...

Page 96: ...CABLE ROUTING 2 69 ...

Page 97: ...t touching the air filter case C Install the clamp with its end facing the left side of the vehicle D Insert the grommet of the air cut off valve into the frame bracket A silicon hydrate or a neutral deter gent soap solution can be coated slightly on it E 1 3 mm F Insert the air cut off valve hose until it reaches its end position G Install the clamp so that its end is positioned below the protrus...

Page 98: ...CABLE ROUTING 2 71 ...

Page 99: ...T BRAKE HOSES 3 15 CHECKING THE REAR BRAKE HOSE 3 15 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 15 CHECKING THE WHEEL BEARING 3 17 CHECKING THE SWINGARM 3 17 ADJUSTING THE DRIVE CHAIN SLACK 3 17 LUBRICATING THE DRIVE CHAIN 3 18 CHECKING AND ADJUSTING THE STEERING HEAD 3 18 ADJUSTING THE HANDLEBAR POSITION 3 19 LUBRICATING THE LEVERS 3 20 LUBRICATING THE PEDAL 3 20 ADJUSTING THE SHIFT PEDAL 3 20...

Page 100: ...ADJUSTING THE HEADLIGHT BEAMS 3 29 REPLACING THE HEADLIGHT BULBS 3 30 ...

Page 101: ...600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve ...

Page 102: ...e Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check operation and for excessive play Lubricate with lith ium soap based grease Every 30000 mi 50000 km 10 Drive chain Check chain slack align ment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughl...

Page 103: ...estand pivot Check operation Apply lithium soap based grease lightly 18 Sidestand switch Check operation and replace if necessary 19 Front fork Check operation and for oil leakage Replace if necessary 20 Shock absorber assembly Check operation and for oil leakage Replace if necessary 21 Engine oil Change warm engine before draining 22 Engine oil filter cartridge Replace 23 Cooling system Check hos...

Page 104: ...seat Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Rubber cover Refer to AIR INDUCTION SYSTEM on page 7 11 2 Disconnect Spark plug caps 3 Remove Spark plugs NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falli...

Page 105: ...r to THROTTLE BODIES on page 7 4 Air cut off valve Rubber cover Refer to AIR INDUCTION SYSTEM on page 7 11 2 Remove Spark plug caps Spark plugs Throttle body Refer to THROTTLE BODIES on page 7 4 Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 8 3 Remove Pickup rotor cover 1 Gasket 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwi...

Page 106: ...event the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 13 0 20 mm 0 005 0 008 in Measure valve clearance 0 25 mm 0 010 in 0 25 mm 0 010 in 0 20 mm 0 ...

Page 107: ...urn smoothly when rotat ed by hand Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts tim ing chain and camshaft caps TIP Refer to CAMSHAFTS on page 5 8 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Turn the crankshaft counterclockwi...

Page 108: ... air screw Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 8 If they cannot synchronized replace the throttle body assembly 4 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 28 EAS20570 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filter element Thrott...

Page 109: ...eck the synchronization again If a air screw was removed clean or replace the throttle bodies TIP The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg 8 Measure Engine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 9 Stop the engine and remove the measuring equipment 10 Adjust Throttle cable free play ...

Page 110: ...11 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Passenger seat Rider se...

Page 111: ...t Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust 2 Adjust Clutch cable free play Handlebar side a Turn the adjusting bolt 1 in direction a or b until the specified clutch cable free play is obtained TIP If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use th...

Page 112: ...nter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21160 ADJU...

Page 113: ... procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator groove a has almost disap peared Replace the brake pads as a set Refer to FRONT BRAKE on page 4 16 EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal posit...

Page 114: ...the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution...

Page 115: ...nd brake hose clamps 1 Check Brake hose Cracks damage wear Replace 2 Check Brake hose clamp Loose Tighten the clamp bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 16 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose Cracks damage wear Replace 2 Check Brake hose clamp Loose Conne...

Page 116: ...ays be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Loading condition 90 188 kg 198 414 lb FZ6RY 90 187 kg 198...

Page 117: ...erload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Spi...

Page 118: ... falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 51 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Tighten the lowe...

Page 119: ...ng gauge at a 90 angle from the handlebar pull the spring gauge and then record the measurement when the handlebar starts to run e Repeat the above procedure on the opposite handlebar f If the steering head tension is out of specifi cation both handlebars should be within specification remove the upper bracket and loosen or tighten the upper ring nut g Reinstall the upper bracket and measure the s...

Page 120: ...Make sure the lower handlebar holders are placed in the parallel position to the vehicle b when installing Once the handlebar is installed check the po sition to make sure it is in the straight line c EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts ...

Page 121: ...vel surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube 1 Damage scratches Replace Oil seal 2 Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on ...

Page 122: ...it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level NOTICE ECA4S81007 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical add...

Page 123: ... min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Side cowling Refer to GENERAL CHASSIS on page 4 1 Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter...

Page 124: ...ne is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 4 Install Oil pressure gauge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification A...

Page 125: ...owever if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Wa...

Page 126: ...led open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move The following procedure applies to all of the coolant drain bolts and copper washers 4 Remove ...

Page 127: ...oolant reservoir with the recommended coolant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 25 TIP Before checking the coolant level wait a few minutes until the coolant has settled EAS20S13003 CHECKING THE FRONT AND REAR BRAKE SWITCH Refer to C...

Page 128: ...hrottle bodies synchro nization should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Remove Left side cowling Refer to GENERAL CHASSIS on page 4 1 Gusset 1 3 Adjust Throttle cable free play TIP When the throttle is opened the accelerator ca ble 1 is pulled Throttle body side a Loosen the adjusting nut 2 on the decelera tor cable b Turn the locknut 3 in direc...

Page 129: ...ine idling speed to change EAS21760 CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8 71 EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8 71 EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizonta...

Page 130: ... the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install Headlight bulb holder...

Page 131: ...RS 4 23 ASSEMBLING THE FRONT BRAKE CALIPERS 4 24 INSTALLING THE FRONT BRAKE CALIPERS 4 24 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 25 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 25 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 26 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 26 REAR BRAKE 4 28 INTRODUCTION 4 33 CHECKING THE REAR BRAKE DISC 4 33 REPLACING THE REAR BRAKE PADS 4 33 REMOVING THE REAR B...

Page 132: ... 4 55 HANDLING THE REAR SHOCK ABSORBER 4 56 DISPOSING OF A REAR SHOCK ABSORBER 4 56 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 SWINGARM 4 58 REMOVING THE SWINGARM 4 59 CHECKING THE SWINGARM 4 59 INSTALLING THE SWINGARM 4 60 CHAIN DRIVE 4 61 REMOVING THE DRIVE CHAIN 4 62 CHECKING THE DRIVE CHAIN 4 62...

Page 133: ... ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Rider seat height position adjuster 1 4 Rear side cover 2 5 Grab bar 1 6 Rear cowling 2 For installation reverse the removal proce dure 1 4 5 6 6 16 Nm 1 6 m kgf 11 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 3 2 4 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 134: ...al coupler 1 6 Left side panel 1 7 Right side panel 1 8 Front cowling left inner panel 1 9 Front cowling right inner panel 1 10 Front cowling assembly 1 11 Sub wire harness coupler 2 For installation reverse the removal proce dure 1 5 Nm 0 15 m kgf 1 1 ft Ibf 7 Nm 0 7 m kgf 5 0 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 7 Nm 0 7 m kgf 5 0 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf 33 Nm ...

Page 135: ...center inner panel 1 7 Right rearview mirror 1 8 Left rearview mirror 1 9 Cowling stay 1 10 Meter assembly 1 11 Sub wire harness 1 12 Head light assembly 1 13 Front cowling 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 1 3 Nm 0 13 m kgf 0 9 ft Ibf 7 Nm 0 7 m kgf 5 0 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 15 Nm 1 5 m kgf 1 1 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf 11 12 1 3 Nm 0 13 ...

Page 136: ... FUEL TANK on page 7 1 1 Clamp screw 4 Loosen 2 Intake air temperature sensor coupler 1 Disconnect 3 Throttle body hose 2 Disconnect 4 Crankcase breather hose 1 Disconnect 5 Air cut off valve hose 1 Disconnect 6 Air filter case 1 For installation reverse the removal proce dure 1 2 3 4 5 6 2 8 Nm 0 28 m kgf 2 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 2 5 Nm 0 25 m kgf 1 8 ft Ibf ...

Page 137: ...er to GENERAL CHASSIS on page 4 1 Rider seat height position adjuster Refer to GENERAL CHASSIS on page 4 1 1 Battery band 1 2 Battery cover 1 3 Negative battery lead 1 4 Positive battery lead 1 5 Battery 1 6 Battery seat 1 For installation reverse the removal proce dure 2 5 Nm 0 25 m kgf 1 8 ft Ibf 1 2 3 4 5 6 ...

Page 138: ... hose holder 3 2 Front brake caliper 2 3 Front wheel axle pinch bolt 1 Loosen 4 Front wheel axle 1 5 Collar 2 6 Front wheel 1 7 Front brake disc 2 For installation reverse the removal proce dure 19 Nm 1 9 m kgf 13 ft Ibf 65 Nm 6 5 m kgf 46 ft Ibf 18 Nm 1 8 m kgf 12 ft Ibf 40Nm 4 0 m kgf 28 ft Ibf 1 1 2 2 3 4 5 5 6 7 7 LT LT ...

Page 139: ...FRONT WHEEL 4 7 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 1 2 2 3 ...

Page 140: ...E FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 15 and CHECKING THE WHEELS on page 3 15 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel tur...

Page 141: ...just the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an...

Page 142: ...he following procedure applies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips 2 Install Collar Wheel axle TIP Install the tire and wheel with the mark 1 point ing in the direction of wheel rotation 3 Tighten Wheel axle Wheel axle pinch bolt NOTICE ECA20S1004 Before tightening the wheel axle push down hard on the handlebar s several times and check if the front fork rebounds smooth...

Page 143: ...en 3 Cap 2 4 Rear wheel axle nut 1 5 Rear wheel axle 1 6 Washer 1 7 Indicator plate 2 8 Drive chain puller 2 9 Rear wheel 1 10 Rear brake caliper assembly 1 For installation reverse the removal proce dure 22 Nm 2 2 m kgf 15 ft Ibf 27 Nm 2 7 m kgf 19 ft Ibf 1 2 3 4 5 6 7 8 1 2 3 8 9 10 S 90 Nm 9 0 m kgf 64 ft Ibf 16 Nm 1 6 m kgf 11 ft Ibf 7 ...

Page 144: ...ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 1 4 Collar 1 5 Oil seal 2 6 Bearing 2 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal proce dure LT 1 2 3 4 5 6 7 8 9 20 Nm 2 0 m kgf 14 ft Ibf 80 Nm 8 0 m kgf 57 ft Ibf 5 6 ...

Page 145: ...REAR WHEEL 4 13 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Oil seal 1 3 Bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure 1 3 4 3 2 ...

Page 146: ...ight collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 15 and CHECKING THE WHEELS on page 3 15 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 EAS22110 CHECKING THE REAR WHEEL DR...

Page 147: ... rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 9 EAS22160 INSTALLING THE REAR WHEEL 1 Lubricate Wheel axle Wheel bearings Oil seal lips 2 Install Collar Rear brake caliper assembly Rear wheel Indicator plate Washer Rear wheel axle 3 Adjust Drive chain slack Refer to ADJ...

Page 148: ...10 FRONT BRAKE Removing the front brake pads Order Job Parts to remove Q ty Remarks 1 Front brake caliper 1 2 Brake pad 2 3 Brake pad spring 2 For installation reverse the removal proce dure 27 Nm 2 7 m kgf 19 ft Ibf 1 2 3 S ...

Page 149: ... reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Union bolt 1 8 Copper washer 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder reservoir 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 1 5 Nm 0 15 m...

Page 150: ...FRONT BRAKE 4 18 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 2 Master cylinder 1 For assembly reverse the disassembly pro cedure 1 2 ...

Page 151: ... SYSTEM on page 3 14 1 Union bolt 2 2 Copper washer 5 3 Brake hose 2 4 Brake caliper 1 5 Brake pad 2 6 Brake pad spring 2 7 Brake caliper bracket 1 For installation reverse the removal proce dure 32 Nm 3 2 m kgf 23 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 27 Nm 2 7 m kgf 19 ft Ibf 1 1 2 2 3 4 5 6 7 6 Nm 0 6 m kgf 4 3 ft Ibf 40 Nm 4 0 m kgf 28 ft Ibf S 6 ...

Page 152: ...Parts to remove Q ty Remarks 1 Brake pad 2 2 Brake caliper piston 2 3 Brake caliper piston dust seal 2 4 Brake caliper piston seal 2 5 Brake pad spring 1 6 Bleed screw 1 For assembly reverse the disassembly pro cedure 6 Nm 0 6 m kgf 4 3 ft Ibf 1 2 3 3 4 4 5 6 BF BF S ...

Page 153: ...ECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Check Brake disc Damage galling Replace 2 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or ri...

Page 154: ...lastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Install Brake caliper 4 Check Brake fluid level Below the minimum level mark b Add the recommended brake fluid to the proper...

Page 155: ...o force out the pistons from the brake caliper WARNING EWA4S81006 Cover the brake caliper piston with a rag Be careful not the get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons c Remove the brake caliper piston dust seals and brake caliper piston seals EAS22390 CHECKING THE FRONT BRAKE CALIPERS 1 Check Brake caliper pistons 1 Rust scr...

Page 156: ...e calipers 1 Install Brake caliper 1 Copper washers 2 Brake hose 3 Union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 41 NOTICE ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Check that the brake caliper slide smoothly on...

Page 157: ...fer to CHECKING THE BRAKE FLUID LEVEL on page 3 12 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Front brake light switch connector from the fron...

Page 158: ... punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 41 NOTICE ECA4S81013 When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the projection b on th...

Page 159: ...r Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 5 Check Brake fluid level Below the minimum level mark c Add the recommended brake fluid ...

Page 160: ...1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad 2 5 Bleed screw 1 6 Brake pad spring 2 For installation reverse the removal proce dure 22 Nm 2 2 m kgf 15 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf 1 2 3 4 4 5 6 6 27 Nm 2 7 m kgf 19 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 2 5 Nm 0 25 m kgf 1 8 ft Ibf S ...

Page 161: ...luid reservoir diaphragm holder 1 3 Rear brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 9 Right footrest assembly 1 10 Rear brake light switch assembly 1 11 Cotter pin 1 12 Rear brake master cylinder 1 For installation reverse the removal proce dure 30 Nm 3 0 m kgf 21 ft Ibf 3 Nm 0 3 m kgf 2 2 ft Ibf 1 2 3 ...

Page 162: ...aster cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 3 Connector 1 4 Bushing 1 For installation reverse the removal proce dure 14 Nm 1 4 m kgf 10 ft Ibf 1 2 3 4 18 Nm 1 8 m kgf 12 ft Ibf ...

Page 163: ...ks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure 22 Nm 2 2 m kgf 15 ft Ibf 1 2 3 4 27 Nm 2 7 m kgf 19 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf S ...

Page 164: ...Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 2 5 Brake caliper piston 1 6 Brake caliper piston dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly pro cedure 2 5 Nm 0 25 m kgf 1 8 ft Ibf 1 2 3 3 4 4 5 6 7 8 BF 5 Nm 0 5 m kgf 3 6 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf S ...

Page 165: ...of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 21 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 21 4 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 21 EAS22580 R...

Page 166: ...from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 Brake caliper 4 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston 1 Brake caliper piston dust seal 2 Brake caliper piston seal 3 a Secure the brake caliper piston with a piece of wood a b Blow compressed...

Page 167: ...seals 2 Check Rear brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the br...

Page 168: ...e type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts The...

Page 169: ...lip from the rear brake master cylinder Master cylinder kit EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit 1 Damage scratches wear Replace 3 Check Brake fluid reservoir 1 Cracks damage Replace Brake fluid...

Page 170: ...rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could caus...

Page 171: ...per level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 12 4 Adjust Brake pedal position c Refer to ADJUSTING THE REAR DISC BRAKE on page 3 13 5 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 27 Brake pedal position 46 5 mm 1 83 in b c ...

Page 172: ... switch 1 9 Throttle grip 1 10 Throttle cable 2 11 Front brake light switch connector 2 Disconnect 12 Front brake master cylinder holder 1 13 Front brake master cylinder 1 14 Upper handlebar holder 2 15 Handlebar 1 For installation reverse the removal proce dure 11 Nm 1 1 m kgf 7 9 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 26 Nm 2 6 m kgf 19 ft Ibf 24 Nm 2 4 m kgf 17 ft Ibf 1 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 173: ...nt brake light switch connector 7 Remove Front brake master cylinder holder 3 Front brake master cylinder Upper handlebar holder Handlebar EAS22880 CHECKING THE HANDLEBAR 1 Check Handlebar 1 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22930 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EW...

Page 174: ...lebar is installed check the po sition to make sure it is in the straight line d 4 Tighten Lower handlebar holder nuts 5 Install Throttle grip 1 Throttle cables Right handlebar switch 2 TIP Align the projections a on the handlebar switch with the holes b in the handlebar 6 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER...

Page 175: ...f the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 28 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLA...

Page 176: ...wheel Refer to FRONT WHEEL on page 4 6 Front brake calipers Refer to FRONT BRAKE on page 4 16 1 Brake hose holder 2 2 Front fender 1 3 Cap bolt 1 Loosen 4 Upper bracket pinch bolt 1 Loosen 5 Under bracket pinch bolt 1 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure 20 Nm 2 0 m kgf 14 ft Ibf 30 Nm 3 0 m kgf 21 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf 4 5 1 5 4 24 Nm 2 4 m kgf 17 f...

Page 177: ...Dust seal 1 6 Oil seal clip 1 7 Damper rod assembly bolt Copper washer 1 1 8 Damper rod assembly 1 9 Oil seal 1 10 Washer 1 11 Inner tube 1 12 Outer tube bushing 1 13 Inner tube bushing 1 14 Oil flow stopper 1 15 Outer tube 1 For assembly reverse the disassembly pro cedure LT 23 Nm 2 3 m kgf 16 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 24 Nm 2 4 m kgf 17 ft Ibf ...

Page 178: ...leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt Spacer Spring seat Fork spring 2 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver NOTICE ECA14180 Do not scratch the inner tube 4 Remove Damper rod assembly bolt Damper ro...

Page 179: ...scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper 2 Damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very ...

Page 180: ...ttom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Damper rod assembly bolt 1 TIP While holding the damper rod assembly with the damper rod holder 2 and T handle 3 tighten the damper rod assembly bolt 4 Install Outer tube bushing 1 with the fork seal driver 2 and fork seal at tachment 3 5 Install Washer Oil seal 1 with the fork seal driv...

Page 181: ...E ECA4S81015 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 Measure Front fork leg oil level a Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and ...

Page 182: ...the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly a Smaller pitch b Lager pitch Lower bracket pinch bolt 30 Nm 3 0 m kgf 22 ft...

Page 183: ...on page 4 44 Handlebar Refer to HANDLEBAR on page 4 40 Fuel tank Refer to FUEL TANK on page 7 1 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM on page 7 11 1 Main switch coupler 2 Disconnect 2 Steering stem nut 1 3 Washer 1 4 Upper bracket 1 5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Rubber washer 1 11 Bearing cover 1 110 Nm 11 0 m kgf 79...

Page 184: ...ve Q ty Remarks 12 Bearing inner race 2 13 Upper bearing Lower bearing 1 1 14 Dust seal 1 15 Bearing outer race 2 For installation reverse the removal proce dure 110 Nm 11 0 m kgf 79 ft Ibf 13 14 15 13 15 T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb 12 12 ...

Page 185: ...ING HEAD 1 Wash Bearing balls Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races 1 from the steer ing head pipe with a long rod 2 and ham mer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bearing race is not i...

Page 186: ...her 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING THE STEERING HEAD on page 4 53 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 50 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease ...

Page 187: ...emove Q ty Remarks Rear side cover Refer to GENERAL CHASSIS on page 4 1 1 Self locking nut washer bolt 1 1 1 2 Self locking nut washer bolt 1 1 1 3 Plate 1 4 Rear shock absorber assembly 1 5 Collar 2 6 Oil seal 2 For installation reverse the removal proce dure 55 Nm 5 5 m kgf 39 ft Ibf 1 1 2 2 3 4 5 5 6 6 M M 51 Nm 5 1 m kgf 36 ft Ibf ...

Page 188: ...eleased before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 20 25 mm 0 79 0 98 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Se...

Page 189: ...EMBLY 1 Lubricate Collar Oil seals 2 Install Rear shock absorber assembly TIP When installing the rear shock absorber assem bly lift up the swingarm 3 Tighten Rear shock absorber assembly upper nut 1 Rear shock absorber assembly lower nut 2 4 Install Rear side cover Refer to GENERAL CHASSIS on page 4 1 Recommended lubricant Molybdenum disulfide grease Rear shock absorber assembly upper nut 51 Nm 5...

Page 190: ...SSEMBLY on page 4 55 Drive sprocket Refer to ENGINE REMOVAL on page 5 1 Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Pivot shaft nut 1 2 Pivot shaft 1 3 Swingarm 1 4 Dust cover 2 5 Spacer 2 6 Oil seal 2 7 Oil seal 2 8 Bearing 4 9 Clamp 1 10 Dust cover 1 11 Drive chain guide 1 For installation reverse the removal proce dure 110 Nm 11 0 m kgf 79 ft Ibf 7 Nm 0 7 m kgf 5 ft Ibf 1 2 3 4 5 6 7 8 9 10...

Page 191: ...play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings and dust covers EAS23370 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surfa...

Page 192: ...ly Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 57 Rear wheel Refer to INSTALLING THE REAR WHEEL on page 4 15 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 Recommended lubricant Lithium soap based grease Bearing installation depth Out side a 4 0 mm 0 16 in In side b 8 5 mm 0 33 in 1 2 1 1 b a a b Pivot shaft nut 110 Nm 11 0 m kgf 79 ft lbf Drive...

Page 193: ...arks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 Shift rod Refer to ENGINE REMOVAL on page 5 1 Swingarm Refer to REMOVING THE SWINGARM on page 4 59 1 Chain cover 1 2 Drive chain 1 For installation reverse the removal proce dure 110 Nm 11 0 m kgf 79 ft Ibf 7 Nm 0 7 m kgf 5 ft Ibf 1 2 LT M M M ...

Page 194: ...n push down on the drive chain to increase its tension 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 remaining dirt c Remove the drive chain from the kerosene and completely dry it NOTICE ECA14290 This vehicle has a...

Page 195: ...ive chain sprockets as a set Bent teeth Replace the drive chain sprock ets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 14 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive chain 3 Install Swingarm Refer...

Page 196: ...CHAIN DRIVE 4 64 ...

Page 197: ...ALVES 5 21 CHECKING THE VALVES AND VALVE GUIDES 5 21 CHECKING THE VALVE SEATS 5 23 CHECKING THE VALVE SPRINGS 5 25 CHECKING THE VALVE LIFTERS 5 26 INSTALLING THE VALVES 5 26 GENERATOR AND STARTER CLUTCH 5 28 REMOVING THE GENERATOR 5 30 REMOVING THE STARTER CLUTCH 5 30 CHECKING THE STARTER CLUTCH 5 30 INSTALLING THE STARTER CLUTCH 5 31 INSTALLING THE GENERATOR 5 31 PICKUP ROTOR 5 33 REMOVING THE PI...

Page 198: ... INSTALLING THE SHIFT SHAFT 5 57 CRANKCASE 5 59 DISASSEMBLING THE CRANKCASE 5 61 CHECKING THE CRANKCASE 5 61 CHECKING THE BEARINGS AND OIL SEALS 5 61 ASSEMBLING THE CRANKCASE 5 61 CRANKSHAFT 5 64 REMOVING THE CONNECTING RODS AND PISTONS 5 66 REMOVING THE CRANKSHAFT ASSEMBLY 5 66 CHECKING THE CYLINDER AND PISTON 5 67 CHECKING THE PISTON RINGS 5 67 CHECKING THE PISTON PINS 5 68 CHECKING THE BIG END ...

Page 199: ...er assembly Refer to CLUTCH on page 5 47 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Washer 1 7 Drive sprocket 1 For installation reverse the removal proce dure LT 85 Nm 8 5 m kgf 61 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 9 Nm 0 9 m kgf 6 5 ft Ibf 1 2 3 5 6 7 LT 16 Nm 1 6 m kgf 11 ft Ibf 1 LT LT 4 ...

Page 200: ...lower mount bolt Refer to RADIATOR on page 6 1 1 Nut 8 2 Bolt 2 3 Bracket 2 4 Muffler COMP 1 5 Cap 1 6 Radiator stay 1 For installation reverse the removal proce dure 20 Nm 2 0 m kgf 14 ft Ibf 1 2 3 2 3 4 5 6 LT 20 Nm 2 0 m kgf 14 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 201: ...L CHASSIS on page 4 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 11 Throttle body Refer to THROTTLE BODIES on page 7 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 Radiator Refer to RADIATOR on page 6 1 1 Clutch cable 1 2 Ground lead 1 3 Starter motor lead 1 Disconnect 4 Sidestand switch coupler 1 Disconnect 5 Stator coil assembly coupler 1 Disconnect 6 Oil level s...

Page 202: ...AL 5 4 Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 8 Speed sensor coupler 1 Disconnect For assembly reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf 8 ...

Page 203: ... bracket assembly 1 Right front engine mounting bolt 2 2 Left front engine mounting bolt 2 3 Self locking nut 2 4 Rear engine mounting bolt 2 5 Engine 1 For installation reverse the removal proce dure 1 2 3 4 55 Nm 5 5 m kgf 39 ft Ibf 4 55 Nm 5 5 m kgf 39 ft Ibf 55 Nm 5 5 m kgf 39 ft Ibf 3 5 ...

Page 204: ...en the bolts 3 Tighten Self locking nut 4 TIP First tighten the lower self locking nut 4 Tighten Left front engine mounting bolts 5 5 Tighten Right front engine mounting bolt 6 6 Install Left footrest bracket assembly 7 Self locking nut 55 Nm 5 5 m kgf 40 ft lbf 1 1 2 3 T R Left front mounting bolt 55 Nm 5 5 m kgf 40 ft lbf Right front engine mounting bolt 55 Nm 5 5 m kgf 40 ft lbf Footrest assemb...

Page 205: ...ve sprocket Washer Drive sprocket nut 1 TIP While applying the rear brake tighten the drive sprocket nut Stake the drive sprocket nut 1 at a cutout a in the drive axle 3 Install Clutch push lever assembly Refer to CLUTCH on page 5 47 Shift arm bolt 16 Nm 1 6 m kgf 11 ft lbf Recommended lubricant Engine oil or chain lubricant suitable for O ring chains Drive sprocket nut 85 Nm 8 5 m kgf 61 ft lbf L...

Page 206: ...er to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 11 Throttle body Refer to THROTTLE BODIES on page 7 4 1 Spark plug cap 4 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing chain guide top side 1 For installation reverse the removal proce dure 1 2 4 5 5 6 13 Nm 1 3 m ...

Page 207: ...Timing chain guide exhaust side Timing chain guide intake side 1 1 6 Intake camshaft cap 3 7 Dowel pin 6 8 Exhaust camshaft cap 3 9 Dowel pin 6 10 Intake camshaft 1 11 Exhaust camshaft 1 12 Camshaft sprocket 2 For installation reverse the removal proce dure 20 Nm 2 0 m kgf 15 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 2 3 M E 5 7 7 1 12 10 20 Nm 2 0 m kgf 15 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 11 1 7 E 7 7 5...

Page 208: ... TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket 5 Remove Timing chain guide Camshaft caps 1 Dowel pins NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the o...

Page 209: ...tigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Intake A 31 850 31 950 mm 1 2539 1 2579 in Limit 31 800 mm 1 2520 in Intake B 24 950 25 050 mm 0 98...

Page 210: ...sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Remove Timing chain tensioner rod 1 Timing chain tensioner spring sea...

Page 211: ... chain tensioner springs tim ing chain tensioner spring seat and timing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and then push the timing chain tensioner rod 3 into the timing chain tensioner housing TIP Do not release the timing chain tensioner clip while pushing the rod into the housing other wise the rod may be ejected c Hook the clip 4 to the timing chain tensioner rod...

Page 212: ...s the right side of the en gine 4 Install Camshaft cap bolts TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out NOTICE ECA4S81016 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing t...

Page 213: ...re face b Camshaft sprocket match mark c Make sure the match marks on the camshaft sprockets are aligned with the edge of the cylinder head d Out of alignment Adjust Refer to the installation steps above 9 Tighten Camshaft sprocket bolts 1 NOTICE ECA4S81017 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the eng...

Page 214: ... 6 6 Intake camshaft Refer to CAMSHAFTS on page 5 8 Exhaust camshaft Refer to CAMSHAFTS on page 5 8 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4 Coolant temperature sensor 1 For installation reverse the removal proce dure 18 Nm 1 8 m kgf 12 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 2 3 3 4 E 19 Nm 1 9 m kgf 13 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 120 1st 3rd 50 Nm 5 0 m kgf 36 ft Ibf 2nd 1 ...

Page 215: ...e scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cy...

Page 216: ...Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Rubber cover Refer to AIR INDUCTION SYSTEM on page 7 11 4 Disconne...

Page 217: ... imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Refer to the following table 8 Install Spark plugs 9 Connect Spark plug caps 10 Install Rubber cover Refer to AIR INDUCTION SYSTEM on page 7 11 Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 St...

Page 218: ...e pad 8 8 3 Intake valve cotter Exhaust valve cotter 16 16 4 Intake valve upper spring seat Exhaust valve upper spring seat 8 8 5 Intake valve spring Exhaust valve spring 8 8 6 Intake valve stem seal Exhaust valve stem seal 8 8 7 Intake valve lower spring seat Exhaust valve lower spring seat 8 8 8 Intake valve Exhaust valve 8 8 9 Intake valve guide Exhaust valve guide 8 8 For installation reverse ...

Page 219: ...nd exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 TIP Remove the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attachment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 TIP Identify the position of each par...

Page 220: ...to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0...

Page 221: ...AS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve margin thickness D intake 0 60 0 80 ...

Page 222: ...and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve fac...

Page 223: ...ication Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 39 08 mm 1 54 in Limit 37 13 mm 1 46 in Free length exhaust 39 08 mm 1 54 in Limit 37 13 mm 1 46 in b Installed length Installed compression spring force intake 132 40 152 40 N 13 50 15 54 kgf 29 76 34 26 lbf Installed compression spring force exhaust 132 40 152 40 N 13 5...

Page 224: ... 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve spring with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment ...

Page 225: ...tting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad 1 Valve lifter 2 with the recommended lubricant TIP Lubricate the valve lifter and valve pad with molybdenum disulfide oil The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 226: ...CHANGING THE ENGINE OIL on page 3 23 1 Left front engine mounting bolt 2 Loosen 2 Stator coil assembly lead coupler 1 Disconnect 3 Generator rotor cover 1 4 Generator rotor cover gasket 1 5 Dowel pin 2 6 Stator coil assembly lead holder 1 7 Stator coil assembly 1 8 Generator rotor 1 9 Starter clutch drive gear 1 10 Starter clutch assembly 1 11 Idler gear shaft 1 LT LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 227: ...ter clutch Order Job Parts to remove Q ty Remarks 12 Idler gear 1 For installation reverse the removal proce dure LT LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf 12 LT E E E 32 Nm 3 2 m kgf 23 ft Ibf 75 Nm 7 5 m kgf 54 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 228: ...with the flywheel puller 2 and flywheel pull er attachment NOTICE ECA13880 To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set s center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolt 1 TIP While holding the generator rotor with the s...

Page 229: ...tch is faulty and must be replaced c When turning the starter clutch drive gear counterclockwise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 tighten the starter clutch bolt Do not allow the sheave holder to touch the projection on ...

Page 230: ...r cover TIP Tighten the generator rotor cover bolts in stages and in a crisscross pattern 6 Fill Engine oil Refer to CHANGING THE ENGINE OIL on page 3 23 7 Install Fuel tank Refer to FUEL TANK on page 7 1 Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 Generator rotor bolt 75 Nm 7 5 m kgf 54 ft lbf Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 ...

Page 231: ...r to CHANGING THE ENGINE OIL on page 3 23 Generator rotor cover Refer to GENERATOR AND STARTER CLUTCH on page 5 28 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Pickup rotor cover 1 3 Pickup rotor cover gasket 1 4 Crankshaft position sensor lead holder 1 5 Crankshaft position sensor 1 6 Pickup rotor 1 For assembly reverse the removal proce dure LT 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m ...

Page 232: ...olt EAS4S81042 INSTALLING THE PICKUP ROTOR 1 Install Pickup rotor 1 Washer Pickup rotor bolt TIP When installing the pickup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 TIP While holding the pickup rotor 2 with the cam shaft wrench 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead ...

Page 233: ...ver TIP When installing the pickup rotor cover align the timing chain guide pins 1 with the holes 2 in the pickup rotor cover Tighten the pickup rotor cover bolts in stages and in a crisscross pattern Pickup rotor cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE New T R 1 2 ...

Page 234: ... on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 Thermostat Refer to THERMOSTAT on page 6 6 1 Speed sensor 1 2 Starter motor lead 1 3 Starter motor 1 For installation reverse the removal proce dure 1 2 3 10 Nm 1 0 m kgf 7 2 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf ...

Page 235: ...front cover 1 3 Lock washer 1 4 Oil seal 1 5 Bearing 1 6 Washer set 1 7 Starter motor rear cover 1 8 Washer set 1 9 Brush holder 1 10 Armature assembly 1 11 Starter motor yoke 1 12 O ring 2 For assembly reverse the disassembly pro cedure 1 2 3 4 5 6 7 8 9 10 11 12 12 3 4 Nm 0 34 m kgf 2 4 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 236: ...tion Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 28 0 mm 1 10 in Mica undercut depth...

Page 237: ... 3 Install Starter motor yoke 1 O ring 2 Starter motor front cover 3 Starter motor rear cover 4 Starter motor assembling bolts 5 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor Starter motor bolts 2 Connect Starter motor lead Starter motor assembling bolt 3 4 Nm 0 ...

Page 238: ...efer to CHANGING THE COOLANT on page 3 26 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Water pump Refer to WATER PUMP on page 6 9 1 Oil level switch lead coupler 1 Disconnect 2 Oil pan 1 3 Oil pan gasket 1 4 Oil strainer 1 5 Oil level switch 1 6 Side cowling bracket 2 7 Oil delivery pipe 1 8 Relief valve assembly 1 9 Oil pipe 1 E 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 3 4 5 6 6 7 8 9 LT LT LT...

Page 239: ... Oil pump assembly 1 12 Dowel pin 2 13 Oil pump drive chain 1 14 Chain guide 1 For installation reverse the removal proce dure E 10 Nm 1 0 m kgf 7 2 ft Ibf 10 11 13 14 LT LT LT 12 Nm 1 2 m kgf 8 7 ft Ibf 43 Nm 4 3 m kgf 30 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 12 12 ...

Page 240: ... remove Q ty Remarks 1 Oil pump cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump rotor housing 1 8 Oil pump driven sprocket 1 For assembly reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 2 3 4 5 6 7 8 ...

Page 241: ... a Outer rotor to oil pump housing clearance b Outer rotor to oil pump cover clearance 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s 2 1 Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 ...

Page 242: ...sage Obstruction Blow out with compressed air EAS25620 CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain 1 Damage stiffness Replace the oil pump drive chain oil pump drive sprocket and oil pump shaft as a set 2 Check Oil pump drive sprocket Cracks damage wear Replace the oil pump drive sprocket and the oil pump drive chain as a set EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner ro...

Page 243: ... of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine EAS25050 INSTALLING THE OIL PAN 1 Install Oil pipe 2 Install Oil pan gasket Oil pan 1 Oil level switch lead holder Oil level switch 2 Engine oil drain bolt WARNING EWA12820 Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil ...

Page 244: ...OIL PUMP 5 46 1 2 ...

Page 245: ...cowling Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 23 1 Dipstick 1 2 Holder 1 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 3 4 5 5 LT LT ...

Page 246: ...MOVAL on page 5 1 1 Push lever case 1 2 Oil seal 1 3 Dowel pin 2 4 Drive chain guide 1 5 Oil seal protector 1 6 Oil seal 1 7 Seat plate 1 8 Push lever 1 9 Spring 1 10 Oil seal 1 11 Bearing 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 2 3 6 7 8 9 10 11 LT E 1 10 Nm 1 0 m kgf 7 2 ft Ibf 4 5 ...

Page 247: ...ction plate 2 6 7 Clutch boss nut 1 8 Clutch boss 1 9 Wire circlip 1 10 Clutch plate 2 Friction plate 3 1 1 11 Spring Spring seat plate 1 1 12 Thrust plate 1 13 Collar Bearing 1 1 14 Clutch housing 1 15 Ball Push rod 1 1 1 For assembly reverse the removal proce dure E E E 95 Nm 9 5 m kgf 68 ft Ibf 8 Nm 0 8 m kgf 5 8 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E E E E E E ...

Page 248: ...tion plates Clutch plates 3 Straighten the clutch boss nut rib 1 4 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder loosen the clutch boss nut 5 Remove Clutch boss nut 1 Washers 2 Clutch boss assembly 3 Thrust plate 4 6 Remove Wire circlip 1 TIP There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wi...

Page 249: ...mage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set TIP Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and...

Page 250: ...using dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLA...

Page 251: ...Replace the push rod EAS25270 INSTALLING THE CLUTCH 1 Install Push rod 1 Ball Clutch housing Bearing Collar 2 Install Spring seat plate 1 Spring 2 TIP Install the spring 2 as shown in the illustration 3 Install Friction plate 3 1 Clutch plate 2 2 TIP Lubricate the engine oil 4 Install Wire circlip 1 5 Install Thrust plate 1 Clutch boss assembly 2 Washers 3 Clutch boss nut 4 Clutch push rod 1 bendi...

Page 252: ...es TIP First install a friction plate and then alternate be tween a clutch plate and a friction plate Install the clutch plate and friction plate as shown in the illustration TIP Install the friction plate 1 3 shifting half phase 10 Install Bearing 1 Push rod 2 2 Pressure plate 3 Clutch springs Clutch spring bolts Clutch boss nut 95 Nm 9 5 m kgf 68 ft lbf Universal clutch holder 90890 04086 YM 910...

Page 253: ...ks match 13 Adjust Push lever position a Loosen locknut 1 of push rod 2 b Return or tighten adjusting nut 3 until the mark of push lever matches the mark of push lever case c Hold the push rod not to move it and tighten the push rod locknut 14 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY on page 3 11 15 Install Drive sprocket cover Refer to ENGINE REMOVAL on page 5 ...

Page 254: ...shift rod Refer to ENGINE REMOVAL on page 5 1 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Stopper lever spring 1 5 Washer 1 6 Circlip 1 7 Washer 1 8 Stopper lever 1 9 Collar 1 10 Shift shaft spring 1 11 Stopper screw 1 12 Oil seal 1 13 Bearing 1 For installation reverse the removal proce dure 16 Nm 1 6 m kgf 11 ft Ibf 1 2 3 5 6 7 8 9 10 11 12 13 LT E 22 Nm 2 2 m kgf 15 ft Ibf E 4 E ...

Page 255: ...pring 2 5 Remove Stopper lever spring 1 Washer 2 Circlip 3 Stopper lever 4 Collar Shift shaft spring 5 EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Collar 3 Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever Stopper lever spring 2 EAS25450 INSTA...

Page 256: ...bly Lubricate the oil seal lips with lithium soap base grease Install the end of the shift shaft spring 2 onto the shift shaft spring stopper Hook the stopper lever spring 3 3 Install Washer 1 Circlip 2 left side of the engine 4 Install Shift rod Shift arm Refer to ENGINE REMOVAL on page 5 1 5 Install Clutch assembly Refer to CLUTCH on page 5 47 1 2 3 4 5 2 1 3 New 1 2 ...

Page 257: ...3 Pickup rotor Refer to PICKUP ROTOR on page 5 33 Clutch Refer to CLUTCH on page 5 47 Water pump Refer to WATER PUMP on page 6 9 Oil pan Refer to OIL PUMP on page 5 40 Oil pump Refer to OIL PUMP on page 5 40 1 Timing chain 1 2 Oil filter cartridge 1 3 Oil filter union bolt 1 4 Lower crankcase 1 5 Dowel pin 3 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 3 4 5 LT LT E E E E E E 12 Nm 1 2 m kgf 8 6 ft Ibf 12 Nm 1 ...

Page 258: ...l proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 6 LT LT E E E E E E 12 Nm 1 2 m kgf 8 6 ft Ibf 12 Nm 1 2 m kgf 8 6 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 70 Nm 7 0 m kgf 50 ft Ibf 24 Nm 2 4 m kgf 17 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 1st 12 Nm 1 2 m kgf 8 6 ft Ibf 80 2nd 20 Nm 2 0 m kgf 14 ft Ibf 1st 12 Nm 1 2 m kgf 8 6 ft Ibf 55 2nd ...

Page 259: ...e Dowel pins 5 Remove Crankshaft journal lower bearing from the lower crankcase TIP Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace...

Page 260: ...mm 3 3 in bolts 1 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 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 LOCTITE M6 100 mm 3 9 in bolt 21 7 Tighten Crankcase bolts 1 10 Refer to ENGINE TIGHTENING TORQUES on page 2 14 Loosen the bolt and retighten to specifica tion torque TIP Tighten t...

Page 261: ...ghtening sequence cast on the crankcase Crankcase bolt M8 65 mm 11 12 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt M6 65 mm 13 14 12 Nm 1 2 m kgf 8 6 ft lbf Crankcase bolt M6 15 27 10 Nm 1 0 m kgf 7 2 ft lbf 4 6 8 2 10 5 7 3 9 1 T R 13 21 16 19 20 27 17 11 12 18 15 14 24 26 22 23 25 ...

Page 262: ...ase Refer to CRANKCASE on page 5 59 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 proce dure 1 2 3 4 4 5 6 7 8 9 10 M M E E E E E 15 Nm 1 5 m kgf 11 ft Ibf 120 ...

Page 263: ...arks Crankcase Separate Refer to CRANKCASE on page 5 59 Connecting rods and connecting rod caps Refer to CRANKSHAFT on page 5 64 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal proce dure 1 2 3 E E ...

Page 264: ... and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Attach the piston pin puller set 4 and turn its handle a counter clockwise to remove the piston pin 2 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the p...

Page 265: ...clearance with the following formula f If out of specification replace the cylinder and the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 65 5...

Page 266: ...Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Top ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 125 mm 0 0049 in a 5 mm 0 20 in Top ring End gap installed 0 25 0 35 mm 0 0098 0 0138 i...

Page 267: ...age the big end bearings must be installed in their origi nal positions a Clean 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 TIP Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Pu...

Page 268: ...DS AND PISTONS on page 5 66 g Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select re placement big end bearings 2 Select Big end bearings P1 P4 TIP The 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 P1 P4 refer ...

Page 269: ...ton pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod faces left when the arrow mark b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Offset Piston ring end gaps 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Lubricate...

Page 270: ...that the characters b on both the connecting rod and connecting rod cap are aligned 8 Tighten Connecting rod bolts WARNING EWA12890 Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTICE ECA14980 Tighten the connecting rod bolts using the plastic region tightening angle method TIP The tightening procedure of the connecting rod bolts is angle controlled therefore tight...

Page 271: ...AL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA4S81028 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 in their original positions a...

Page 272: ...nce is out of specification select replacement crankshaft journal bear ings 2 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crankshaft web and the numbers 1 stamped into the low er crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size fo...

Page 273: ...the upper crankcase TIP Align the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 2 Install Crankshaft 3 Install Lower crankcase Refer to CRANKCASE on page 5 59 1 J1 J2 J3 J4 J5 ...

Page 274: ...se Refer to CRANKCASE on page 5 59 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Shift fork guide bar retainer 1 5 Shift fork guide bar 1 6 Shift fork L 1 7 Shift fork R 1 8 Plate 1 For installation reverse the removal proce dure 12 Nm 1 2 m kgf 8 6 ft Ibf 1 2 3 4 5 6 7 8 LT LT E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 275: ...emarks 1 Shift fork guide bar retainer 1 2 Shift fork guide bar 1 3 Shift drum assembly 1 4 Bearing housing 1 5 Bearing 1 6 Main axle assembly 1 7 Bearing 1 8 Shift fork C 1 9 Oil pipe 1 10 O ring 3 12 Nm 1 2 m kgf 8 6 ft Ibf 1 2 3 4 5 6 7 8 9 10 LT E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf E LT ...

Page 276: ...1 Washer 1 2 1st wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M E M M M M ...

Page 277: ...ly Order Job Parts to remove Q ty Remarks 16 Circlip 1 17 Washer 1 18 2nd wheel gear 1 19 Collar 1 20 Oil seal 1 21 Collar 1 22 Bearing 1 23 Circlip 1 24 Drive axle 1 For installation reverse the removal proce dure 16 17 18 19 23 24 M M E M 22 20 21 M M M ...

Page 278: ...d lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 14 M M E 15 13 12 M M M 11 10 9 ...

Page 279: ... forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a...

Page 280: ...smission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace EAS20S13007 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned ...

Page 281: ... Shift fork guide bar retainer TIP Stake the main axle bearing housing bolts at a cutout in the main axle bearing housing The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and ...

Page 282: ...ure that the drive axle bearing circlip a is inserted into the grooves in the upper crank case Make sure that the drive axle bearing projec tion b is aligned to the groove in the upper crankcase 3 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly Shift fork guide bar retainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE T R a b ...

Page 283: ...6 3 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 284: ...ERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Radiator fan lead coupler 1 Disconnect 2 Coolant reservoir hose 1 3 Fast idle plunger outlet hose 1 4 Water pump breather hose 1 5 Radiator outlet hose 1 6 Radiator inlet breather hose 1 7 Radiator inlet hose 1 8 Oil cooler outlet hose 1 9 Radiator 1 10 Radiator cap 1 11 Rubber cover 1 10 Nm 1 0 m kgf 7 2 ft Ibf 4 ...

Page 285: ...ob Parts to remove Q ty Remarks 12 Coolant reservoir cover Coolant reservoir 1 1 13 Coolant reservoir cap 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 4 Nm 0 4 m kgf 2 9 ft Ibf LT 7 Nm 0 7 m kgf 5 1 ft Ibf 12 13 ...

Page 286: ...ake sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to ELECTRICAL COMPONENTS on page 8 71 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressur...

Page 287: ...o CHANGING THE ENGINE OIL on page 3 23 1 Oil cooler outlet hose 1 2 Union bolt 1 3 Washer 1 4 Oil cooler 1 5 O ring 1 6 Oil cooler inlet hose 1 7 Oil cooler inlet pipe 1 8 Water jacket joint hose 1 9 Water jacket joint 1 10 O ring 1 11 Water pump outlet hose 1 12 Radiator outlet hose 1 For installation reverse the removal proce dure 63 Nm 6 3 m kgf 45 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 LT E 10 Nm 1...

Page 288: ...ricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 23 4 Check Cooling system Leaks Repair or replace any faul...

Page 289: ...SIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 1 Radiator inlet hose Radiator inlet breather hose 1 1 2 Thermostat cover 1 3 Thermostat 1 For installation reverse the removal proce dure 1 2 3 LT 12 Nm 1 2 m kgf 8 6 ft Ib...

Page 290: ...ostat housing cover 1 Cracks damage Replace EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing up 2 Install Thermostat cover TIP Before installing the thermostat cover to the cyl inder head lubricate the O rings with a thin coat of lithium soap based grease 3 Fill Cooling system with the specified amount of the recom mended c...

Page 291: ...THERMOSTAT 6 8 Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 292: ...p unless the coolant level is extremely low or the coolant contains engine oil Coolant Drain Refer to CHANGING THE COOLANT on page 3 26 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump breather hose 1 Disconnect 4 Water pump 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 3 4 LT LT ...

Page 293: ...ts to remove Q ty Remarks 1 Water pump cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 Water pump housing 1 9 O ring 1 For assembly reverse the disassembly pro cedure 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 3 4 5 6 7 8 9 ...

Page 294: ... water pump housing 5 Remove Bushing 5 Gasket 6 from the impeller shaft with a thin flat head screwdriver TIP Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing 1 Water pump cover 2 Impeller shaft 3 Bushing Gasket Water pump seal 4 Oil seal 5 Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet hose Radiator outlet h...

Page 295: ...eller shaft tilt Out of specification Repeat steps 3 and 4 NOTICE ECA20S1005 Make sure the bushing and gasket are flush with the impeller 5 Install Impeller shaft Circlip O ring Copper washer Water pump cover EAS26590 INSTALLING THE WATER PUMP 1 Install O ring Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Bearing driver 40...

Page 296: ...her TIP Install the radiator outlet hose with white a mark positioned outside 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 26 4 Check Cooling system Leaks Repair or replace the faulty part 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 Wat...

Page 297: ...TANK 7 3 THROTTLE BODIES 7 4 CHECKING THE THROTTLE BODY JOINTS 7 5 CHECKING THE FUEL INJECTORS 7 7 INSTALLING THE INJECTORS 7 7 CHECKING THE INJECTOR PRESSURE 7 7 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 CHECKING THE FUEL PRESSURE 7 9 ADJUSTING THE THROTTLE POSITION SENSOR 7 10 AIR INDUCTION SYSTEM 7 11 CHECKING THE AIR INDUCTION SYSTEM 7 14 INSTALLING THE AIR INDUCTION SYSTEM 7 14 CANISTER F...

Page 298: ...ge 4 1 1 Cover 1 2 Fuel hose 1 Disconnect 3 Fuel sender coupler 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel tank drain hose 1 6 Fuel tank breather hose 1 7 Rollover valve 1 For California only 8 Fuel tank 1 9 Fuel pump bracket 1 10 Fuel pump 1 11 Gasket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 8 9 10 11 12 Nm 1 2 m kgf 8 7 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 4 Nm 0 4 m k...

Page 299: ...d dam aging the fuel pump installation surface EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly 2 Check Diaphragms and gaskets Turn fatigue cracks Replace fuel p...

Page 300: ...d TIP Install the fuel hose securely onto the fuel rail until a distinct click is heard To install the fuel hose onto the fuel rail slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 2 Install Fuel tank breather hose Fuel tank drain hose Fuel sender coupler Fuel pump coupler TIP The paint mark a of both the fuel tank breather hose 1 and the fuel tank d...

Page 301: ...r to AIR INDUCTION SYSTEM on page 7 11 1 Sub wire harness coupler 2 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Fuel hose 1 Disconnect 4 Fast idle plunger outlet hose 1 Disconnect 5 Fast idle plunger inlet hose 1 Disconnect 6 Canister purge hose 1 Disconnect For California only 7 Throttle cable 2 Disconnect 8 Throttle body joint clamp screw 4 Loosen 9 Throttle bodies 1 10 Thrott...

Page 302: ...he following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 4 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 ...

Page 303: ... Disconnect 4 Sub wire harness 1 5 Negative pressure hose 1 6 Canister purge hose 1 For California only 7 Intake air pressure sensor 1 8 Throttle position sensor 1 9 Fast idle plunger 1 10 Fuel rail 1 11 Fuel injector 4 12 Throttle bodies 1 For installation reverse the removal proce dure 5 8 9 12 3 5 Nm 0 35 m kgf 2 5 ft Ibf 3 5 Nm 0 35 m kgf 2 5 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf 10 11 11 7 3 3 3 1...

Page 304: ... 8 29 EAS2S31099 INSTALLING THE INJECTORS 1 Install the injectors to the fuel rail making sure to install them in the correct direction 2 Install a seal onto the end of each injector 3 Install the injector assemblies to the throttle bodies 4 Check the injector pressure after the injectors are installed to the throttle bodies Refer to CHECKING THE INJECTOR PRESSURE on page 7 7 EAS2S31098 CHECKING T...

Page 305: ...ed solvent Do not use any caustic carburetor cleaning solution Do not apply cleaning solvent directly to any plastic parts sensors or seals Do not directly push the throttle valves to open them Do not remove the bolts which not instruct ed as so Do not touch the synchronizing screw a otherwise the throttle body synchroniza tion will be affected Do not touch the throttle adjust screw b TIP Check th...

Page 306: ...ages a in each throttle body or in the space b between the throttle valve shaft and the throttle body 3 Check Fuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent NOTICE ECA2S31070 Do not use any caustic carburetor cleaning solution b Blow out all of the passages with com pressed air 4 Check Fuel pulsation damper Cracks damage Replace the fuel rail as sembly NOT...

Page 307: ...er to the wire harness b Connect the digital circuit tester to the throttle position sensor c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws Positive tester probe Yellow 1 Negative tester probe Black Blue 2 Dig...

Page 308: ...AIR INDUCTION SYSTEM 7 11 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 2 3 6 ...

Page 309: ...7 12 1 Air filter case 2 Air cut off valve hose air filter case air cut off valve 3 Air cut off valve 4 Air cut off valve hose air cut off valve reed valve 5 Air cut off valve hose air cut off valve reed valve 6 Reed valve ...

Page 310: ...n page 4 1 1 Air cut off valve hose air cut off valve reed valve 1 Disconnect 2 Air cut off valve hose air cut off valve reed valve 1 Disconnect 3 Rubber cover 1 4 Air cut off valve hose air filter case air cut off valve 1 Disconnect 5 Air cut off valve bracket 1 6 Air cut off valve 1 7 Reed valve cap 2 8 Reed valve assembly 2 9 Plate 4 For installation reverse the removal proce dure 1 2 3 4 5 6 7...

Page 311: ...t off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve 1 Reed valve stopper Re...

Page 312: ... page 4 28 Right rear side cover Refer to GENERAL CHASSIS on page 4 1 1 Fuel tank breather hose rollover valve to canis ter 1 Disconnect 2 Canister purge hose 1 Disconnect 3 Canister 1 4 Fuel tank breather hose canister to atmo sphere 1 Disconnect 5 Canister holder 1 For installation reverse the removal proce dure 16 Nm 1 6 m kgf 11 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 ...

Page 313: ...RCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 31 TROUBLE SHOOTING CHART 8 33 DIAGNOSTIC MODE 8 34 TROUBLESHOOTING DETAILS 8 35 OTHER DIAGNOSTIC MONITORING CODES 8 65 FUEL PUMP SYSTEM 8 67 CIRCUIT DIAGRAM 8 67 TROUBLESHOOTING 8 69 ELECTRICAL COMPONENTS 8 71 CH...

Page 314: ...TOR COIL 8 88 CHECKING THE RECTIFIER REGULATOR 8 89 CHECKING THE HORN 8 89 CHECKING THE ENGINE OIL LEVEL SWITCH 8 89 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 90 CHECKING THE FUEL SENDER 8 90 CHECKING THE SPEED SENSOR 8 91 CHECKING THE RADIATOR FAN MOTOR 8 91 CHECKING THE COOLANT TEMPERATURE SENSOR 8 92 CHECKING THE THROTTLE POSITION SENSOR 8 92 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 93 CHEC...

Page 315: ......

Page 316: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 317: ...h 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 21 Engine stop switch 31 Crankshaft position sensor 32 ECU engine control unit 37 Ignition coil 1 4 38 Ignition coil 2 3 39 Spark plug 53 Clutch switch 65 Ignition fuse ...

Page 318: ... the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 86 NG Replace the spark plug caps OK 5 Check the ignition coils Refer to CHECKING THE IGNITION COIL on page 8 86 NG Replace the ignition coils OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 87 NG Replace the crankshaft position sensor OK 7 Check the main switch Refer to CHEC...

Page 319: ...clutch switch OK 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 83 NG Replace the relay unit OK 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition system s wiring OK Replace the ECU engine control unit ...

Page 320: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 321: ...6 3 Battery 4 Main fuse 5 Starter relay 6 Starter motor 10 Main switch 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 21 Engine stop switch 22 Start switch 53 Clutch switch 65 Ignition fuse ...

Page 322: ...er is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the st...

Page 323: ...STAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Diode 13 Starter relay 14 Starter motor ...

Page 324: ...er motor OK 4 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 83 NG Replace the relay unit OK 5 Check the starter relay Refer to CHECKING THE RELAYS on page 8 83 NG Replace the starter relay OK 6 Check the main switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the main switch OK 7 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 75 N...

Page 325: ...efer to CHECKING THE SWITCHES on page 8 75 NG Replace the right handlebar switch OK 12 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting system s wiring OK The starting system circuit is OK ...

Page 326: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 327: ...CHARGING SYSTEM 8 12 1 AC magneto 2 Rectifier regulator 3 Battery 4 Main fuse ...

Page 328: ... AND CHARG ING THE BATTERY on page 8 80 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 88 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 89 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCU...

Page 329: ...CHARGING SYSTEM 8 14 ...

Page 330: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 331: ...gine control unit 48 High beam indicator light 50 Meter light 54 Dimmer switch 60 Front left turn signal light 61 Front right turn signal light 62 License plate light 63 Tail brake light 64 Headlight 65 Ignition fuse 66 Signal fuse 67 Headlight fuse 68 Headlight relay ...

Page 332: ... on page 8 79 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 8 80 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 75 NG The dimmer switch is faulty Replace the left ha...

Page 333: ...LIGHTING SYSTEM 8 18 ...

Page 334: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 335: ...unit 42 Oil level warning light 43 Neutral indicator light 44 Tachometer 45 Multi function meter 47 Coolant temperature warning light 49 Turn signal indicator light 51 Oil level switch 55 Turn signal switch 56 Horn switch 57 Horn 58 Rear left turn signal light 59 Rear right turn signal light 60 Front left turn signal light 61 Front right turn signal light 63 Tail brake light 65 Ignition fuse 66 Si...

Page 336: ... on page 8 80 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the horn switch Refer to CHECKING THE SWITCHES on...

Page 337: ...ake light switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the turn signal indicator light bulb and socket NG Replace the turn signal indicator light bulb socket or both OK 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the lef...

Page 338: ...aling system s wiring OK This circuit is OK 1 Check the oil level warning light bulb and socket NG Replace the oil level warning light bulb socket or both OK 2 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the oil level switch OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair the signaling system ...

Page 339: ...e speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 91 NG Replace the speed sensor OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly ...

Page 340: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 341: ...COOLING SYSTEM 8 26 3 Battery 4 Main fuse 9 Radiator fan fuse 10 Main switch 11 Radiator fan motor relay 12 Radiator fan motor 28 Coolant temperature sensor 32 ECU engine control unit 65 Ignition fuse ...

Page 342: ...efer to CHECKING THE SWITCHES on page 8 75 NG Replace the main switch OK 4 Check the radiator fan motor Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 91 NG The radiator fan motor is faulty and must be replaced OK 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 83 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature Refer to CHECKING THE COOLAN...

Page 343: ...COOLING SYSTEM 8 28 ...

Page 344: ...FUEL INJECTION SYSTEM 8 29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 345: ...ensor 26 Intake air pressure sensor 27 Intake air temperature sensor 28 Coolant temperature sensor 29 Lean angle sensor 30 Speed sensor 31 Crankshaft position sensor 32 ECU engine control unit 33 Fuel injector 1 34 Fuel injector 2 35 Fuel injector 3 36 Fuel injector 4 37 Ignition coil 1 4 38 Ignition coil 2 3 39 Spark plug 40 Air induction system solenoid 45 Multi function meter 46 Engine trouble ...

Page 346: ... bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and when the start switch is being pushed If the warning light does not come on under these con ditions the warning light bulb may be defective EAS27362 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL If the ECU detects an abnormal signal from a sensor while the vehicle is bei...

Page 347: ... The ECU takes fail safe actions in two ways one in which the sensor output is set to a prescribed value and the other in which the ECU directly operates an actuator Details on the fail safe actions are given in the table below ...

Page 348: ...able Diagnostic code No 62 Engine operation is not normal or the engine trouble warning light is on Engine trouble warning light may not come on even if the engine operation is not normal The engine trouble warning light does not come on Check the operation of following sensors and ac tuators in the diagnostic mode Refer to Diagnos tic code table 01 Throttle position sensor throttle angle 30 Ignit...

Page 349: ...at applies to the item that was verified with the fault code num ber by pressing the SELECT and RESET buttons TIP The diagnostic code number appears on the clock LCD 01 70 To decrease the selected diagnostic code number press the RESET button Press the RESET button to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press th...

Page 350: ...sition sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Crank the engine and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection o...

Page 351: ... fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 12 Symptom Normal signals are not received from the crank position sensor Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitoring code No Meter display Checking method Order Item components and probable cause Check or maintenance job Sensor inspection ...

Page 352: ...o fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indi cation No fault code indicat...

Page 353: ...fer to CHECKING THE INTAKE AIR PRES SURE SENSOR on page 8 93 Place the main switch to the ON position and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 13 Symptom Open or short circuit of intake air pressure sensor lead Fail safe action Engine startup Possible Riding Possible Diagnostic mo...

Page 354: ... Sensor inspection procedure 1 The intake air pressure sensor hose is damaged disconnected clogged twisted or bent Repair or replace the sensor hose Starting the engine and operating it at idle Fully close the throttle and check the fault recovery 2 Intake air pressure sen sor malfunction Check in the diagnostic mode Code No D03 When engine is stopped Atmospheric pressure at the current altitude a...

Page 355: ...and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of sub har ness coupler Check the connection of the coupler is secure Remove the coupler and check each pin for be...

Page 356: ...de of range Replace the throttle position sensor Refer to CHECKING THE THROTTLE POSI TION SENSOR on page 8 92 Place the main switch to the ON position and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 8 ECU malfunction Replace the ECU Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine...

Page 357: ...ount ing pinched mounting or hard mounting Make sure that the mounting position is cor rect Refer to ADJUSTING THE THROTTLE POSI TION SENSOR on page 7 10 Place the main switch to the ON position and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 2 Throttle position sensor malfunction Check in the diagnostic mode Code No D01 When throttle...

Page 358: ...ain har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indi cation when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Check the ne...

Page 359: ...d Make sure that the meter indication is close to the ambient temperature during cold starting Order Item components and probable cause Check or maintenance job Sensor inspection procedure 1 Connection of coolant temperature sensor cou pler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair...

Page 360: ...e indi cation No fault code indicated Recovered Fault code indicated Check the next step 5 Coolant temperature sensor malfunction Check in the diagnostic mode Code No D06 During cold starting A temperature close to the ambient temperature is indicated Indication is incorrect Replace the coolant tem perature sensor Refer to CHECKING THE COOLANT TEMPERA TURE SENSOR on page 8 92 Place the main switch...

Page 361: ...to the ON position and check the fault code indi cation No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position a...

Page 362: ...ault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 22 Symptom Open or short circuit of intake air temperature sensor lead Fail safe action Engine startup Possible Riding Possible Diagnostic monitoring code No 05 Meter display 30 to 120 C During cold starting A temperature close to the ambient temperature is indicated During hot starting Ambient temperature plus...

Page 363: ... and probable cause Check or maintenance job Sensor inspection procedure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch is first turned OFF 2 Sensor installation status Check for a loose mount ing pinched mounting or hard mounting Make sure that the mounting position is cor rect ...

Page 364: ...t code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or replace the wire harness Start and idle the engine for approximately 5 sec onds Then check the fault code indica...

Page 365: ...lace the defective ECU Fault code No 33 Symptom Ignition coil primary lead malfunction Fail safe action Engine startup Possible depending on the number of failed cylinders Riding Possible depending on the number of failed cylinders Diagnostic monitoring code No 30 Meter display Each ignition coil turns On or Off 5 times per second The engine warning light flashes according to the On Off switching ...

Page 366: ...he fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Start and idle the engine for approximately 5 sec onds Then check the fau...

Page 367: ...lace the defective ECU Fault code No 34 Symptom Ignition coil primary lead malfunction Fail safe action Engine startup Possible depending on the number of failed cylinders Riding Possible depending on the number of failed cylinders Diagnostic monitoring code No 31 Meter display Each ignition coil turns On or Off 5 times per second The engine warning light flashes according to the On Off switching ...

Page 368: ...ult code indicated Check the next step 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the harness Rotate the main switch to the OFF position first and then rotate it to the ON position again Then check the fault code indication No fault ...

Page 369: ... speed of the rear wheel increases This value is cumulative and is not reset each time the wheel is prevented from rotating Order Checkpoints Inspection method Locate the malfunction Check in the diagnostic mode Code No D07 Rotate the rear wheel and make sure that the indication value increases Malfunction Go to the Speed sensor system malfunction section below Check in the diagnostic mode Code No...

Page 370: ...connection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Continuity of speed sen sor leads Continuity of wire har ness Open or short circui...

Page 371: ...nnection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Reconnect or repair the coupler 3 Continuity of wire har ness Open or short circuit Replace the wire har ness White red Black blue 4 Continuity of leads between neutral switch and relay unit coupler Open or short circuit Replace the neutral switch Sky blue Sky blue 5 Neutral switch ...

Page 372: ...l pump coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Connection of fuel injec tor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair r...

Page 373: ...ration adjusted for cylinders 2 and 3 2 01 is indicated in Diag nostic mode Code No D60 EEP ROM data error for adjustment of CO con centration of cylinders 1 and 4 Change the CO concen tration of cylinders 1 and 4 and rewrite in EEP ROM After this adjustment is made the memory is not recovered when the main switch is turned OFF and ON again Replace the ECU Place the main switch to the ON position ...

Page 374: ...tery and main switch Red Red Between the main switch and ignition fuse Brown Blue Brown Blue Between the ignition fuse and ECU Red White Red White Start and idle the engine for approximately 5 sec onds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Battery malfunction Check the battery volt age Refer to CHECKING AND CHARGING THE BA...

Page 375: ...enance job Sensor inspection procedure 1 ECU malfunction Replace the ECU Place the main switch to the ON position Then check that no fault code indicated Fault code No 70 Symptom Engine idling stop engine has been left idling The ECU automatically stops the engine after 20 minutes if it is left idling Fail safe action Able to start engine Able to drive vehicle Diagnostic monitoring code No Meter d...

Page 376: ... check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Continuity of...

Page 377: ...ck each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Continuity of wir...

Page 378: ...r and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Continui...

Page 379: ...coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main har ness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bend ing wear or locking Poor connection Con nect it securely or repair replace the wire harness 3 Co...

Page 380: ...ery second Illuminates the engine trouble warning light Check the operating sound of the AI system solenoid five times 51 Radiator fan motor relay Actuates the radiator fan motor relay for five cycles every five second ON 2 seconds OFF 3 seconds Illuminates the engine trouble warning light Check the operating sound of the Radiator fan motor relay five times 52 Headlight relay Actuates the headligh...

Page 381: ...alfunction code exists Fault code 24 If more than one code number is detected the display changes every two seconds to show all the detected code num bers are shown the dis play repeats To reinstate set the engine stop switch to Diagnos tic code No Item Meter display Checking method ...

Page 382: ...FUEL PUMP SYSTEM 8 67 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 383: ...PUMP SYSTEM 8 68 3 Battery 4 Main fuse 7 Fuel injection system fuse 10 Main switch 13 Relay unit 15 Fuel injection system relay 21 Engine stop switch 23 Fuel pump 32 ECU engine control unit 65 Ignition fuse ...

Page 384: ...arge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the main switch OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 75 NG Replace the right handlebar switch OK 5 Check the fuel injection system relay Refer to CHECKING THE RELAYS on page 8 83 NG Replace the relay unit OK 6 Check the fuel pump Refer to CHECKING THE ...

Page 385: ...FUEL PUMP SYSTEM 8 70 ...

Page 386: ...ELECTRICAL COMPONENTS 8 71 EAS27970 ELECTRICAL COMPONENTS 2 1 3 4 5 6 10 8 9 11 7 12 13 14 15 ...

Page 387: ...witch 2 Clutch switch 3 Air induction system solenoid 4 Battery 5 Starter relay 6 Fuse box 7 Neutral switch 8 Rear brake light switch 9 Sidestand switch 10 Speed sensor 11 Oil level switch 12 Radiator fan motor 13 Horn 14 Ignition coil 15 Main switch ...

Page 388: ...ELECTRICAL COMPONENTS 8 73 2 1 3 4 5 6 10 8 9 7 11 12 13 ...

Page 389: ...erature sensor 3 Fuel pump 4 Intake air pressure sensor 5 Lean angle sensor 6 Relay unit 7 Turn signal relay 8 Radiator fan motor relay 9 Headlight relay 10 ECU engine control unit 11 Rectifier regulator 12 Coolant temperature sensor 13 Throttle position sensor ...

Page 390: ...ELECTRICAL COMPONENTS 8 75 EAS27980 CHECKING THE SWITCHES 7 8 9 12 11 14 10 4 1 2 3 5 6 13 ...

Page 391: ...nal switch 4 Dimmer switch 5 Clutch switch 6 Sidestand switch 7 Start switch 8 Engine stop switch 9 Front brake light switch 10 Oil level switch 11 Neutral switch 12 Rear brake light switch 13 Left handlebar switch lead coupler 14 Right handlebar switch lead coupler ...

Page 392: ... to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at ...

Page 393: ... all of the bulbs 1 Remove Bulb WARNING EWA4B51012 Since the headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA4B51010 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it ...

Page 394: ...onnect the digital circuit tester to the fuse and check the continuity b If the digital circuit tester indicates no continu ity replace the fuse 3 Replace Blown fuse a Turn 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 WARNING EWA1...

Page 395: ...arge a VRLA Valve Regulated Lead Ac id battery a special constant voltage bat tery charger is required Using a conventional battery charger will damage the battery TIP Since VRLA batteries are sealed it is not possi ble to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the ...

Page 396: ...roded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an VRLA battery stabilizes about 30...

Page 397: ...nect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA battery A vari able voltage charger is recommended d Charge the battery until the battery s charg ing ...

Page 398: ...eter with tachom eter YU A1927 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 1 2 3 4 R L W R B R L W L L W L Y R W L B B R Sb B Y Lg 3 1 2 4 Result Continuity between 3 and 4 1 Positive battery terminal 2...

Page 399: ...nnect the digital circuit tester to the turn signal relay terminal as shown b Turn the main switch to ON c Measure the turn signal relay output voltage 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input voltage DC 12 V Digital circuit tester 90890 03174 Model 88 Multimeter with tachom ete...

Page 400: ...k plug cap from the spark plug b Connect the ignition checker 1 as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Black Yellow 2 No continuity Positive tester probe Black Yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Black Red 3 No continuity Positive tes...

Page 401: ...e spark plug cap as shown c Measure the spark plug cap resistance EAS28080 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the digital circuit tester Ω 1 to the ignition coil as shown c Measure the primary coil resistance 1 Ignition checker 2 Spark plug cap Resistance 10 0 k...

Page 402: ...0 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the digital circuit tester DC 20 V to the lean angle sensor coupler as shown Secondary coil resistance 12 00 18 00 kΩ Ω Ω Ω Digital circuit tester 90890 03174 Model 88 Multimeter with tachom eter YU A...

Page 403: ...likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the crank shaft position sensor a Connect the digital circuit tester Ω 1 to the stator coil coupler as shown Positive tester ...

Page 404: ...esistance Out of specification Replace a Disconnect the horn leads from the horn ter minals b Connect the digital circuit tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Replace EAS28190 CHECKING THE ENGINE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Rectifier regulator output voltage 14 V at 5000 r min Digital circuit tester 90890 03174 Model 88 Mul...

Page 405: ...uel pump coupler Fuel sender coupler Fuel hose from the fuel pump Refer to FUEL TANK on page 7 1 2 Remove Fuel pump from the fuel tank Refer to FUEL TANK on page 7 1 3 Check Fuel sender resistance Out of specification Replace the fuel pump Engine oil level gauge Minimum level position resis tance 114 126 Ω Ω Ω Ω at 20 C 68 F Maximum level position resis tance 484 536 Ω Ω Ω Ω at 20 C 68 F Digital c...

Page 406: ...to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue Each with full rotation of the front wheel the voltage reading should cycle from 0 V to 5 0 V to 0 V to 5 0 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler Sender unit resistance full 19 0 21 0 Ω Ω Ω...

Page 407: ... not get wet c Place a thermometer 3 in the coolant d Slowly heat the coolant and then let it cool down to the specified temperature e Measure the coolant temperature sensor re sistance 3 Install Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification ...

Page 408: ...filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circuit tester Ω 100 to the intake air temperature sensor terminal as shown Tester posit...

Page 409: ...ELECTRICAL COMPONENTS 8 94 b Measure the intake air temperature sensor resistance Positive tester probe Black Blue 1 Negative tester probe Brown White 2 1 2 ...

Page 410: ...ELECTRICAL COMPONENTS 8 95 ...

Page 411: ...ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 ...

Page 412: ... body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil s Cracked or broken ignition coil...

Page 413: ...AR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level I...

Page 414: ...embly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improper...

Page 415: ...ake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn sig...

Page 416: ...t 44 Tachometer 45 Multi function meter 46 Engine trouble warning light 47 Coolant temperature warning light 48 High beam indicator light 49 Turn signal indicator light 50 Meter light 51 Oil level switch 52 Left handlebar switch 53 Clutch switch 54 Dimmer switch 55 Turn signal switch 56 Horn switch 57 Horn 58 Rear left turn signal light 59 Rear right turn signal light 60 Front left turn signal lig...

Page 417: ......

Page 418: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 419: ...FZ6RY C 2009 WIRING DIAGRAM XJ6N 2009 SCHÉMA DE CÂBLAGE FZ6RY C A W D 09 1 22 9 55 ページ 1 ...

Page 420: ...FZ6RY C 2009 WIRING DIAGRAM XJ6N 2009 SCHÉMA DE CÂBLAGE FZ6RY C A W D 09 1 22 9 55 ページ 2 ...

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