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Yamaha MBK MW125 2014, Service Manual

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CRANKSHAFT

5-65

3. Measure:

• Crankshaft width

Out of specification

→

Replace the crank-

shaft assembly.

4. Check:

• Crankshaft sprocket “1”

Damage/wear

→

Replace the crankshaft as-

sembly.

• Bearing “2”

Cracks/damage/wear

→

Replace the crank-

shaft assembly.

EAS31243

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.

EAS31244

CHECKING THE BEARING

1. Check:

• Bearing

Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement

→

Replace.

EAS31245

CHECKING THE OIL PUMP DRIVE GEAR

1. Check:

• Oil pump drive gear

Damage/wear

→

Replace.

EAS30791

INSTALLING THE CRANKSHAFT

1. Install:

• Crankshaft assembly “1”

TIP

Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt “3”,
adapter “4”, and crankshaft installer spacer “5”.

NOTICE

ECA13970

To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.

Crank assembly width

45.45–45.50 mm (1.789–1.791 in)

1

2

Crankshaft installer pot

90890-01274

Installing pot

YU-90058

Crankshaft installer bolt

90890-01275

Bolt

YU-90060

Adapter (M12)

90890-01278

Adapter #3

YU-90063

Crankshaft installer spacer

90890-04156

1

5

4

3

2

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Summary of Contents for MBK MW125 2014

Page 1: ...SERVICE MANUAL MW125 2014 MW125F 2015 2CM F8197 E0...

Page 2: ...W125F 2015 SERVICE MANUAL 2014 by Thai Yamaha Motor Co Ltd First edition May 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Thai Yamaha Motor Co Ltd is...

Page 3: ...g nificant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable TIP Designs and specifi...

Page 4: ...int 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...

Page 5: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Page 6: ......

Page 7: ...EAS10003 TABLE OF CONTENTS 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...

Page 8: ......

Page 9: ...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 BEARI...

Page 10: ...EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS30003 MODEL LABEL The model label 1 is affixed to the inside of the stor...

Page 11: ...ns of the en gine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tune...

Page 12: ...ration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air p...

Page 13: ...he battery charged by a Yamaha dealer Speedometer The speedometer shows the vehicle s traveling speed Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of th...

Page 14: ...DO the tripme ter modes TRIP 1 and TRIP 2 the oil change tripmeter mode OIL TRIP and the V belt re placement tripmeter mode BELT TRIP in the following order ODO TRIP 1 TRIP 2 OIL TRIP BELT TRIP ODO Wh...

Page 15: ...km 600 mi the next periodic oil change interval will be at every 4000 km 2500 mi thereafter V belt replacement indicator V BELT This indicator come on at every 20000 km 12500 mi to indicate that the...

Page 16: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Page 17: ...air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after on...

Page 18: ...ener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the faste...

Page 19: ...a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Re...

Page 20: ...5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never i...

Page 21: ...refore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely an...

Page 22: ...k Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be s...

Page 23: ...er to the list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration...

Page 24: ...90890 01275 Bolt YU 90060 5 65 5 66 Adapter M12 90890 01278 Adapter 3 YU 90063 5 65 5 66 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 29 Tappet adjusting tool 90890 01311 Six piece t...

Page 25: ...3 8 drive 60 cm long YM 01326 4 71 4 72 Clutch spring holder 90890 01337 Universal clutch compressor holder YM 33285 5 39 5 42 Locknut wrench 90890 01348 Locknut wrench YM 01348 5 39 5 43 Radiator ca...

Page 26: ...0 01372 Replacement 38 mm YM A5142 1 4 73 Oil seal guide 90890 01384 Oil seal guide YM 33299 5 42 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 16 3 17 4 85 Sheave holder 90890...

Page 27: ...re adapter 90890 03181 Fuel pressure adapter YM 03181 7 3 Compression gauge extension S 90890 03195 5 1 Yamaha diagnostic tool 90890 03231 3 7 3 8 7 11 7 11 7 11 7 12 8 29 Test harness lean angle sens...

Page 28: ...guide reamer 5 0 mm YM 04099 5 23 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 22 5 27 Mechanical seal installer 90890 04145 6 9 Crankshaft installer...

Page 29: ...NING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 LUBRICATION SYSTE...

Page 30: ...2CM5 GBR 2CM7 AUS NZL Dimensions Overall length 1905 mm 75 0 in Overall width 735 mm 28 9 in Overall height 1215 mm 47 8 in Seat height 780 mm 30 7 in Wheelbase 1310 mm 51 6 in Ground clearance 120 mm...

Page 31: ...50 Recommended engine oil grade API service SG type or higher JASO standard MA or MB Engine oil quantity Quantity disassembled 0 90 L 0 95 US qt 0 79 Imp qt Periodic oil change 0 80 L 0 85 US qt 0 70...

Page 32: ...mm 0 0032 in Valve valve seat valve guide Valve clearance cold Intake 0 08 0 12 mm 0 0032 0 0047 in Exhaust 0 16 0 20 mm 0 0063 0 0079 in Valve dimensions Valve head diameter intake 25 90 26 10 mm 1 0...

Page 33: ...31 0 048 mm 0 0012 0 0019 in Diameter 52 362 52 385 mm 2 0615 2 0624 in Measuring point from piston skirt bottom 7 0 mm 0 28 in Piston pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in Limit...

Page 34: ...on ratio 1 000 Secondary reduction ratio 9 533 44 15 x 39 12 Gear ratio 2 361 0 794 1 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Air filter Air filter element O...

Page 35: ...04 in Lateral wheel runout limit 0 5 mm 0 02 in Front tire Type Tubeless Size 90 80 14M C 43P Manufacturer model CHENG SHIN M6231 Wear limit front 1 5 mm 0 06 in AUS NZL 1 6 mm 0 06 in CYP FIN GBR GRC...

Page 36: ...0 28 in Limit 1 5 mm 0 06 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Specified brake fluid YAMAHA GENUINE BRAKE FLUID DOT 4 Steering Steering...

Page 37: ...pe Coil spring oil damper Rear shock absorber assembly travel 97 0 mm 3 82 in Spring free length 209 6 mm 8 25 in CYP FIN GBR GRC IRL POL SVK SVN TUR Spring installed length 199 6 mm 7 86 in Spring ra...

Page 38: ...coil resistance 0 400 0 600 W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 0 15 0 V Battery Model YTZ7V Voltage capacity 12 V 6 0 Ah Manufacturer YUASA Hea...

Page 39: ...83 in Mica undercut depth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal relay Relay type Condenser Built...

Page 40: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 41: ...lbf Coolant reservoir nut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Radiator cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Radiator bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M12 1 2 5 Nm 0 25 m kgf 1...

Page 42: ...m kgf 7 2 ft lbf Cylinder head stud bolt M8 2 15 Nm 1 5 m kgf 11 ft lbf Cylinder head plug M12 1 28 Nm 2 8 m kgf 20 ft lbf Oil check bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Spark plug M10 1 13 Nm 1 3 m k...

Page 43: ...TIGHTENING TORQUES 2 14 Cylinder head tightening sequence Radiator fan case tightening sequence 6 5 2 3 4 1 1 3 5 4 1 2...

Page 44: ...1 ft lbf Rear fender screw M5 4 1 5 Nm 0 15 m kgf 1 1 ft lbf Tail brake light assembly bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear reflector screw M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Wire harness holder...

Page 45: ...7 m kgf 5 1 ft lbf Handlebar switch screw right side M5 2 2 4 Nm 0 24 m kgf 1 7 ft lbf Handlebar switch screw left side M5 2 2 4 Nm 0 24 m kgf 1 7 ft lbf Front brake master cylinder holder bolt M6 2...

Page 46: ...cket bolt M6 6 13 Nm 1 3 m kgf 9 4 ft lbf Front fender bracket screw M4 4 1 0 Nm 0 10 m kgf 0 72 ft lbf Front brake hose holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Front fork leg bolt M10 4 50 Nm 5 0...

Page 47: ...heel axle nut 1 2 Temporarily install the swingarm mounting bolt upper side 2 then the swingarm mounting bolt lower side 3 3 Tighten the rear wheel axle nut to 125 Nm 12 5 m kgf 90 ft lbf 4 Tighten th...

Page 48: ...nd Piston piston rings and cylinder inner surface O rings crankshaft assembly bearing Oil pump drive gear Cam chain sprocket Oil pump driven gear shaft O rings fuel injector Starter clutch one way pin...

Page 49: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 20...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 7 6 5 4 3 2 1...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Oil nozzle 5 Camshaft 6 Valve stem end 7 Rocker arm...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS30021 LUBRICATION DIAGRAMS 1 3 2...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Oil strainer 2 Oil pump assembly 3 Camshaft...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 2 3 4 5 1...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Camshaft 5 Rocker arm Valve stem end...

Page 56: ...COOLING SYSTEM DIAGRAMS 2 27 EAS20020 COOLING SYSTEM DIAGRAMS 1 2 4 3 5 6 9 8 3 4 5 7...

Page 57: ...DIAGRAMS 2 28 1 Radiator cap 2 Coolant reservoir hose 3 Cooling system air bleed hose 4 Radiator inlet hose 5 Radiator outlet hose 6 Radiator 7 Water pump assembly 8 Water pump outlet hose 9 Water pu...

Page 58: ...CABLE ROUTING 2 29 EAS20021 CABLE ROUTING Handlebar front and rear view A C B 11 1 2 2 4 4 7 10 10 1 1 10 8 9 5 6 5 6 10 8 9 1 2 3 4 7...

Page 59: ...6 Left handlebar switch lead 7 Wire harness 8 Right handlebar switch lead 9 Front brake light switch lead 10 Throttle cable decelerator cable 11 Wire harness strap A Make sure that the wire harness st...

Page 60: ...CABLE ROUTING 2 31 Steering head left side view A A A A 1 2 2 2 1 1 2 1 2 1 2 B...

Page 61: ...d sensor lead 2 Front brake hose A Fasten the speed sensor lead to the front brake hose with the holder Align the holder with the white paint marks on the speed sensor lead and front brake hose B Inne...

Page 62: ...CABLE ROUTING 2 33 Front wheel left side view 1 2 1 1 1...

Page 63: ...CABLE ROUTING 2 34 1 Speed sensor lead 2 Front brake hose...

Page 64: ...CABLE ROUTING 2 35 Throttle body and rear wheel left and right side view 2 2 1 1 A B A C D D E E F G H D E 3...

Page 65: ...white paint mark on the cylinder head breather hose C Install the breather hose throttle body to cylinder with its yellow paint mark facing upward D Point the ends of the hose clamp in the direction...

Page 66: ...CABLE ROUTING 2 37 Front frame right side view...

Page 67: ...Sidestand switch lead 4 Main switch lead 5 Throttle cable accelerator cable 6 Throttle cable decelerator cable 7 Horn receiver unit lead 8 Seat lock cable A Connect the horn connectors to the horn ma...

Page 68: ...CABLE ROUTING 2 39 Rear frame right side view 1 2 3 4 5 5 5 6 7 8 8 9 10 11 12 13 A 8 8 8 14 15 15 15 16 17 19 18 23 22 18 17 15 24 19 B K J 21 8 15 H G I 8 8 5 5 15 15 20 F 11 E D C...

Page 69: ...gative battery lead with the plastic band B Fasten the crankshaft position sensor stator coil assembly lead with the holder on the air filter case joint C When fastening the wire harness and leads wit...

Page 70: ...CABLE ROUTING 2 41 Front frame left side view 1 2 3 4 5 6 7 8 9 10 A 4 7 5 6 11 13 12...

Page 71: ...ake hose 4 Rear brake hose 5 Throttle cable decelerator cable 6 Throttle cable accelerator cable 7 Seat lock cable 8 Sidestand switch lead 9 Headlight coupler 10 Front turn signal light coupler 11 Aux...

Page 72: ...CABLE ROUTING 2 43 Rear frame left side view 7 8 7 6 5 9 10 11 12 13 14 15 16 18 17 1 2 3 4 5 6 7 B G I H A 13 19 20 14 5 D C E F...

Page 73: ...ed between the storage box and the frame B Align the white tape on the seat lock cable with the center of the holder C Route the throttle cable decelerator cable which is identified by white tape on t...

Page 74: ...CABLE ROUTING 2 45 Front frame top view 1 2 3 4 2 3 4 5 6 12 10 11 13 7 8 8 9 A 2 3 5 4 6...

Page 75: ...ignal light lead 6 Wire harness 7 Seat lock cable 8 Rear brake hose 9 Sidestand switch lead 10 Throttle cable accelerator cable 11 Throttle cable decelerator cable 12 Front left turn signal light lead...

Page 76: ...CABLE ROUTING 2 47 Rear frame top view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A B...

Page 77: ...regulator lead 9 Rear right turn signal light lead 10 Tail brake light lead 11 Rear left turn signal light lead 12 Seat lock cable 13 Fuel hose 14 Fuse box A Route the rectifier regulator lead and fr...

Page 78: ...CABLE ROUTING 2 49...

Page 79: ...CHECKING THE REAR BRAKE HOSE 3 11 CHECKING THE BRAKE FLUID LEVEL 3 11 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 12 CHECKING THE WHEELS 3 13 CHECKING THE TIRES 3 14 CHECKING THE WHEEL BEARINGS 3 15 CHECKI...

Page 80: ...CHECKING THE THROTTLE GRIP OPERATION 3 24 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 24 ADJUSTING THE HEADLIGHT BEAM 3 25 REPLACING THE HEADLIGHT BULB 3 25...

Page 81: ......

Page 82: ...The annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 20000 km 12000 mi repeat the maintenance inte...

Page 83: ...screws are properly tight ened Every 12000 km 7200 mi 14 Front brake lever pivot shaft Lubricate with silicone grease 15 Rear brake lever pivot shaft Lubricate with silicone grease 16 Unified brake sy...

Page 84: ...calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers...

Page 85: ...well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replac...

Page 86: ...ttle cable guide Spark plug cap Spark plug 2 Cylinder head cover 3 Cylinder head cover gasket 3 Remove Radiator cover 1 4 Move Radiator 1 TIP Move the rear of the radiator outward 5 Measure Valve clea...

Page 87: ...ylinder head cover gasket Cylinder head cover Spark plug Spark plug cap Cylinder head breather hose 10 Install Center side covers Storage box Center cover Refer to GENERAL CHASSIS 1 on page 4 1 GENERA...

Page 88: ...t it warm up for several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the ISC idle s...

Page 89: ...ool For more information refer to the opera tion manual of the Yamaha diagnostic tool 1 Connect the Yamaha diagnostic tool to the connector For information about connecting the Yamaha diagnostic tool...

Page 90: ...air filter element into the air filter case make sure that the sealing surfaces are aligned to prevent any air leaks EAS31181 CLEANING THE V BELT CASE AIR FILTER ELEMENT TIP Check the V belt case air...

Page 91: ...633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves a almost disap peared Replace the brake pa...

Page 92: ...hose 1 Cracks damage wear Replace 2 Check Brake hose holder Loose Tighten the holder bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Repla...

Page 93: ...to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake syste...

Page 94: ...imes h Fully pull the brake lever and hold it in posi tion i Loosen the bleed screw TIP Loosening the bleed screw will release the pres sure and cause the brake lever to contact the handlebar grip j T...

Page 95: ...the tire immediately 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury...

Page 96: ...ECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEELS on page 4 28 and CHECKING THE REAR WHEEL on page 4 33 E...

Page 97: ...directions If any bind ing is felt remove the steering column or lower brackets and check the upper and low er bearings Refer to STEERING HEAD on page 4 81 Refer to FRONT ARMS AND LOWER BRACKETS on p...

Page 98: ...LINK ARM BEARINGS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Elevate Front wheels Refer to REMOVING THE FRONT...

Page 99: ...ment Repair Refer to FRONT FORKS on page 4 65 EAS30654 CHECKING THE REAR SUSPENSION 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of i...

Page 100: ...engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Dipstick 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil co...

Page 101: ...ange indicator Refer to INSTRUMENT FUNCTIONS on page 1 4 EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is up...

Page 102: ...ant reservoir hose 1 2 Drain Coolant from the coolant reservoir 3 Remove Radiator cover 1 4 Remove Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator...

Page 103: ...0 Bleed Air bleed a Tighten the radiator cap start the engine and warm it up for several minutes b Touch the radiator inlet hose and make sure that it is warm make sure the thermostat is opened c Rev...

Page 104: ...and second ary pulleys Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 TIP Replace the V belt every 20000 km 12500 mi of operation 3 Install V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on...

Page 105: ...peed should be adjusted properly a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighte...

Page 106: ...il it has cooled down 4 Install Headlight bulb Secure 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 o...

Page 107: ...BLY COVER 4 10 REMOVING THE UPPER LEG SHIELD 4 11 INSTALLING THE UPPER LEG SHIELD 4 11 GENERAL CHASSIS 6 4 12 REMOVING THE UPPER HANDLEBAR COVER 4 13 INSTALLING THE UPPER HANDLBAR COVER 4 13 GENERAL C...

Page 108: ...41 REMOVING THE FRONT BRAKE CALIPERS 4 42 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 42 CHECKING THE FRONT BRAKE CALIPERS 4 42 ASSEMBLING THE FRONT BRAKE CALIPERS 4 43 INSTALLING THE FRONT BRAKE CALIPER...

Page 109: ...LOWER BRACKETS 4 79 CHECKING THE FRONT ARMS TIE ROD AND LOWER BRACKETS 4 79 INSTALLING THE LOWER BRACKETS 4 79 INSTALLING THE FRONT ARMS 4 79 STEERING HEAD 4 81 REMOVING THE STEERING COLUMN 4 85 CHECK...

Page 110: ...CHASSIS 1 Removing the battery and seat Order Job Parts to remove Q ty Remarks 1 Center cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Seat 1 1 5 Nm 0...

Page 111: ...er side covers and rear side cov ers e Slide the center cover forward and remove it EAS31190 INSTALLING THE CENTER COVER 1 Install Center cover a Close the seat b Slide the center cover rearward and i...

Page 112: ...to remove Q ty Remarks 1 Fuse box cover 1 2 Fuse box 1 3 Starter relay coupler 1 Disconnect 4 Starter relay 1 5 Fuel tank overflow hose 1 6 Storage box 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf...

Page 113: ...rom the projections on the stor age box b Unhook the slots in the fuse box cover from the projections on the storage box EAS31261 INSTALLING THE FUSE BOX COVER 1 Install Fuse box cover a Fit the slots...

Page 114: ...at Storage box Refer to Removing the storage box 1 Rear cover 1 2 Grab bar bracket rear side 1 3 Grab bar bracket front side 1 4 Grab bar 2 5 Rear side cover 2 6 Center side cover 2 1 5 Nm 0 15 m kgf...

Page 115: ...AS31264 REMOVING THE SIDE COVERS The following procedure applies to both of the side covers 1 Remove Side cover a Remove the screws and quick fastener screws b Unhook the projections on the side cover...

Page 116: ...l brake light assembly b Fit the projections on the side cover into the slots in the rear fender c Install the screws and quick fastener screws T R Rear side cover screw front side 7 Nm 0 7 m kgf 5 1...

Page 117: ...Removing the side covers 1 Tail brake light coupler 1 Disconnect 2 Rear turn signal light coupler 1 Disconnect 3 Tail brake light assembly 1 4 Rear reflector 1 5 Rear fender 1 6 Flap 1 10 Nm 1 0 m kg...

Page 118: ...2 Windshield bracket 2 3 Front upper panel 1 4 Meter assembly cover 1 5 Meter assembly coupler 1 Disconnect 6 Meter assembly 1 7 Upper leg shield 1 2 1 3 4 4 4 5 6 4 7 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R...

Page 119: ...PANEL 1 Install Front upper panel a Push the front upper panel rearward to fit the projection into the grommet in the headlight unit b Fit the projections on the front upper panel into the slots in t...

Page 120: ...1 Remove Upper leg shield a Pull the upper leg shield rearward to unhook the projections from the slots in the lower leg shield EAS31271 INSTALLING THE UPPER LEG SHIELD 1 Install Upper leg shield a Fi...

Page 121: ...ve Q ty Remarks Upper leg shield Refer to Removing the meter assembly 1 Rearview mirror 2 TIP The rearview mirror right side has left hand threads 2 Upper handlebar cover 1 3 Lower handlebar cover 1 1...

Page 122: ...ctions on the upper handle bar cover from the slots in the lower handle bar cover EAS31273 INSTALLING THE UPPER HANDLBAR COVER 1 Install Upper handlebar cover a Fit the projections on the upper handle...

Page 123: ...Lower leg shield cover 2 3 Headlight coupler 1 Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Front turn signal light coupler 1 Disconnect 6 Front cowling assembly 1 7 Lower leg shield 1 12 1 3 5...

Page 124: ...into the slots in the front side panels and front cowling assembly b Install the screws EAS31276 REMOVING THE LOWER LEG SHIELD COVERS The following procedure applies to both of the lower leg shield co...

Page 125: ...orward to re move the grommets from the projections on the windshield bracket EAS31279 INSTALLING THE FRONT COWLING ASSEMBLY 1 Install Front cowling assembly a Fit the grommets in the front cowling as...

Page 126: ...ard and remove it EAS31281 INSTALLING THE LOWER LEG SHIELD 1 Install Lower leg shield a Slide the lower leg shield downward and in stall it b Install the screws T R Lower leg shield screw center 4 0 N...

Page 127: ...ignal light bulb 2 6 Headlight bracket 2 7 Side cowling 2 8 Front side panel 2 9 Turn signal light 2 10 Headlight coupler 1 Disconnect 11 Headlight bulb cover 1 12 Headlight bulb 1 13 Headlight unit 1...

Page 128: ...dure applies to both of the front center panels 1 Install Front center panel a Fit the projections on the front center panel into the slots in the side cowling EAS31284 REMOVING THE FRONT SIDE PANELS...

Page 129: ...GENERAL CHASSIS 8 4 20 a Fit the projections on the front side panel into the slots in the side cowling...

Page 130: ...om cover 2 2 Front cowling upper inner panel 2 3 Front cowling lower inner panel 1 4 Footrest board 1 5 Footrest board bracket 2 New New 4 4 3 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1...

Page 131: ...ottom cover from the grommet in the front cowling lower inner pan el EAS31287 INSTALLING THE BOTTOM COVERS The following procedure applies to both of the bottom covers 1 Install Bottom cover a Fit the...

Page 132: ...cover Air filter case duct Air filter case duct cover 1 1 1 2 Air filter element 1 3 Cylinder head breather hose 1 Disconnect 4 Air filter case joint clamp screw 1 Loosen 5 Air filter case Air filter...

Page 133: ...ction a on the air filter case joint between the projections b on the air filter case 2 Install Air filter case joint clamp 1 to the air filter case joint 2 TIP Align the projection a on the air filte...

Page 134: ...and so that the front wheel is elevated 1 Mudguard 1 2 Speed sensor 1 Right side only 3 Speed sensor lead guide 1 Right side only 4 Front brake caliper 1 5 Wheel cap 1 6 Clip 1 7 Front wheel axle nut...

Page 135: ...1 Right side 11 Collar 1 Left side 12 Speed sensor rotor 1 Right side only 13 Front brake disc 1 14 Fitting plate 1 15 Front wheel assembly 1 LS New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 f...

Page 136: ...sassembling the front wheels Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front wheels 1 Oil seal 2 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 New New New...

Page 137: ...of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings...

Page 138: ...n powder dust solvent Clean TIP The speed sensor rotor is installed on the inner side of the wheel hub When cleaning the speed sensor rotor be careful not to damage the surface of the rotor EAS30151 A...

Page 139: ...that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to...

Page 140: ...or with the stamped mark a facing away from the wheel Install the brake disc with the stamped mark b facing toward the wheel Tighten the bolts in stages 2 Check Front brake disc Refer to CHECKING THE...

Page 141: ...he rear wheel and brake disc Order Job Parts to remove Q ty Remarks Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 88 1 Rear wheel 1 2 Washer 1 3 Rear brake disc 1 LT LT LT L...

Page 142: ...TIRES on page 3 14 and CHECKING THE WHEELS on page 3 13 2 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEELS on page 4 28 EAS30165 INSTALLING THE REAR WHEEL REAR BRAK...

Page 143: ...ing procedure applies to both of the front brake calipers 1 Front brake caliper bolt 2 2 Speed sensor lead guide 1 Right side only 3 Front brake caliper 1 4 Brake pad pin 1 5 Front brake pad 2 6 Brake...

Page 144: ...ylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever cover 1 5 Front brake light switch connector 2 Disconnec...

Page 145: ...ring 1 12 Front brake lever knocker 1 13 Brake lever cable joint 1 14 Brake hose union bolt 1 15 Copper washer 2 16 Front brake hose 1 17 Front brake master cylinder holder 1 18 Front brake master cyl...

Page 146: ...FRONT BRAKE 4 37 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 New BF 1 BF S 2 S...

Page 147: ...front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Speed s...

Page 148: ...rake pad pin 1 2 Front brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 1 6 Brake caliper piston dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 9 Brake cali...

Page 149: ...er to FRONT WHEELS on page 4 25 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle o...

Page 150: ...an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad spring and new brake pads TIP Ins...

Page 151: ...aliper piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper...

Page 152: ...brake caliper piston dust seals and brake caliper piston seals EAS30175 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper...

Page 153: ...DING THE HYDRAULIC BRAKE SYSTEM on page 3 12 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 EAS30179 REMOVING TH...

Page 154: ...tial to in sure safe vehicle operation NOTICE ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown TIP Turn the handlebar t...

Page 155: ...nt 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 6 Bleed Brake sys...

Page 156: ...1 2 Rear brake caliper bolt 2 3 Rear brake caliper 1 4 Brake pad pin cap 1 5 Brake pad pin 1 6 Rear brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 5 Nm 0 25 m...

Page 157: ...Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever cover 1 5 Rear brake light switch connector...

Page 158: ...ds 10 Rear brake lever 1 11 Rear brake lever knocker 1 12 Brake hose union bolt 1 13 Copper washer 2 14 Rear brake hose 1 15 Rear brake master cylinder holder 1 16 Rear brake master cylinder 1 1 0 Nm...

Page 159: ...REAR BRAKE 4 50 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 New 1 2 S BF S BF...

Page 160: ...fer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Rear brake hose holder 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Rear brake hose 1 5 Rear brake caliper bolt 2 6 Rear brake caliper 1 10...

Page 161: ...5 Brake pad support 1 6 Brake caliper bracket 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 11 Brake caliper body 1 2 5 Nm 0 25 m kgf 1...

Page 162: ...ake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 40 4 Measure...

Page 163: ...mum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Ref...

Page 164: ...on Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obs...

Page 165: ...Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may r...

Page 166: ...ster cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap Brake master cylinder reservoir...

Page 167: ...r over the end of the bolt b 5 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may c...

Page 168: ...ake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 8 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SY...

Page 169: ...brake master cylinder holder 1 5 Front brake master cylinder 1 6 Right handlebar switch coupler 1 Disconnect 7 Right handlebar switch 1 8 Throttle cable 2 Disconnect 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 7...

Page 170: ...ler 1 Disconnect 15 Rear brake light switch coupler 1 Disconnect 16 Left handlebar switch 1 17 Handlebar grip 1 18 Brake hose holder 2 19 Handlebar bolt nut 1 1 20 Handlebar 1 2 0 Nm 0 20 m kgf 1 4 ft...

Page 171: ...TALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar TIP Align the slots a in th...

Page 172: ...ower bolt 6 Install Throttle grip 1 Throttle cables 2 Right handlebar switch 3 TIP Lubricate the end of the throttle cables and the inside of the throttle grip with a thin coat of lith ium soap based...

Page 173: ...to CHECKING THE THROTTLE GRIP OPERATION on page 3 24 9 Adjust Rear brake lever free play Refer to ADJUSTING THE REAR BRAKE LEVER FREE PLAY on page 3 10 Throttle grip free play 3 0 7 0 mm 0 12 0 28 in...

Page 174: ...eft front fender side 2 Front brake hose speed sensor lead holder 1 Right front fender side 3 Front arm cover 1 4 Front fender 1 5 Front fender panel 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 3 Nm 0 13 m kgf...

Page 175: ...essary to replace the outer tubes 8 Cap bolt 2 Loosen 9 Lower bracket pinch bolt 4 10 Front fork leg 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T...

Page 176: ...to both of the front fork legs 1 Front fork leg bolt 2 NOTICE ECA21660 Do not remove the front fork leg bolts un less it is necessary to replace the outer tubes 2 Dowel pin 1 3 Front fork cap bolt 2...

Page 177: ...ont fork damper rod bolt 1 Main tube side only 9 Front fork outer tube bolt 1 Guide tube side only 10 Copper washer 2 11 Damper rod 1 Main tube side only 12 Damper rod ring 1 Main tube side only 13 Re...

Page 178: ...15 Oil seal 2 16 Washer 2 17 Outer tube bushing 2 18 Inner tube bushing 2 19 Spring 1 Main tube side only 20 Oil flow stopper 1 Main tube side only 21 Outer tube 2 18 Nm 1 8 m kgf 13 ft Ibf T R LT LT...

Page 179: ...fore loosening the lower bracket pinch bolts support the front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTICE ECA19110 The fr...

Page 180: ...nner tube as this may dangerously weaken it 2 Measure main tube side only Fork spring free length a Out of specification Replace 3 Check main tube side only Damper rod Damage wear Replace Obstruction...

Page 181: ...ing the damper rod assembly with the hexagon bit socket 15 mm 2 and T handle 3 tighten the front fork damper rod bolt 6 Install Outer tube bushing 1 Washer with the fork seal driver attachment 2 and f...

Page 182: ...e 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 Fork seal driver weight 90890 01367 Replac...

Page 183: ...up and down to distribute the fork oil EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg 1 Temporarily tighten the lower...

Page 184: ...the front fork leg bolts stroke the front forks several times First tighten the lower front fork leg bolt then the upper bolt 5 Tighten Cap bolts TIP If the cap bolts are difficult to tighten slightly...

Page 185: ...brake hose joint holder 1 3 Front brake hose joint 1 4 Tie rod 1 5 Tie rod joint 3 TIP The tie rod joint bolt center is a one way bolt 6 Front arm 2 6 1 5 5 4 2 3 5 6 6 1 LS LS LS LS LS LS LS LS LS L...

Page 186: ...edure applies to both of the lower brackets 1 Bearing race cover 1 2 Upper ring nut 1 3 Lock washer 1 4 Center ring nut 1 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 2 1 3 4 5 7 6 1st 38 Nm...

Page 187: ...ring inner race 1 10 Upper bearing 1 11 Lower bearing 1 12 Lower bearing inner race 1 13 Dust seal 1 14 Lower bearing outer race 1 15 Upper bearing outer race 1 16 Steering stopper 1 8 9 10 15 14 11 1...

Page 188: ...ECKING THE STEERING HEAD on page 4 85 4 Check Front arms Tie rod Tie rod joints Lower brackets Bends cracks damage Replace EAS31222 INSTALLING THE LOWER BRACKETS 1 Lubricate Upper bearings Lower beari...

Page 189: ...icle on the centerstand b Face the handlebar straight ahead c Mark the tread center at the most forward point on each front tire d Measure the width A between the marks e Rotate the front tires 180 un...

Page 190: ...Order Job Parts to remove Q ty Remarks Handlebar Refer to HANDLEBAR on page 4 60 Lower brackets Refer to FRONT ARMS AND LOWER BRACKETS on page 4 76 1 Horn 1 2 Main switch 1 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 191: ...ront lower link arm 1 4 Lower bracket pipe 2 5 Luggage hook 1 6 Main switch bracket 1 7 Rear lower link arm 1 1 2 3 4 4 30 Nm 3 0 m kgf 22 ft Ibf T R 88 Nm 8 8 m kgf 64 ft Ibf T R 88 Nm 8 8 m kgf 64 f...

Page 192: ...emove Q ty Remarks 1 Upper ring nut 1 2 Lock washer 1 3 Center ring nut 1 4 Rubber washer 1 5 Lower ring nut 1 6 Steering column 1 7 Upper bearing cover 1 1 2 3 4 7 6 5 1st 38 Nm 3 8 m kgf 27 ft Ibf 2...

Page 193: ...earing inner race 1 9 Upper bearing 1 10 Lower bearing 1 11 Lower bearing inner race 1 12 Dust seal 1 13 Collar 1 14 Lower bearing outer race 1 15 Upper bearing outer race 1 8 9 15 14 10 11 12 13 1st...

Page 194: ...ing column Bearing races steering column a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Install new bearing races NOTICE ECA14270 If the bearing race is not in...

Page 195: ...lower link arm bolts to front lower link arm 11 temporarily tighten Front lower link arm bolts to lower bracket pipe 12 temporarily tighten Upper link arm 13 Upper link arm bolts to lower bracket pipe...

Page 196: ...h bracket bolt 88 Nm 8 8 m kgf 64 ft lbf Rear lower link arm bolt to lower bracket pipe 110 Nm 11 m kgf 80 ft lbf Front lower link arm bolt to lower bracket pipe 110 Nm 11 m kgf 80 ft lbf Upper link a...

Page 197: ...CHASSIS 4 on page 4 8 Muffler Refer to ENGINE REMOVAL on page 5 3 Radiator cover Refer to RADIATOR on page 6 1 1 Rear wheel axle nut 1 2 Rear brake hose holder 1 3 Rear brake caliper 1 New New New LS...

Page 198: ...absorber assembly 2 5 Spacer 1 6 Swingarm 1 7 Collar 1 8 Oil seal 1 9 Circlip 1 10 Bearing 1 11 Oil seal 1 New New New LS LS LS 8 5 9 11 6 7 4 10 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft I...

Page 199: ...e brake lever when removing the brake caliper EAS31229 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorb...

Page 200: ...Tighten the rear wheel axle nut 2 then the swingarm mounting bolts 3 4 5 Install Rear shock absorber assemblies TIP Tighten the rear shock absorber assembly nuts and bolts temporarily and then tighte...

Page 201: ...VING THE CAMSHAFT 5 18 CHECKING THE CAMSHAFT 5 18 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 18 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 2...

Page 202: ...5 42 INSTALLING THE PRIMARY SHEAVE V BELT AND SECONDARY SHEAVE 5 42 INSTALLING THE V BELT CASE 5 44 STARTER CLUTCH 5 46 CHECKING THE STARTER WHEEL 5 48 CHECKING THE STARTER CLUTCH 5 48 CHECKING THE T...

Page 203: ...NG THE CRANKSHAFT ASSEMBLY 5 64 CHECKING THE CRANKSHAFT ASSEMBLY 5 64 CHECKING THE CRANKCASE 5 65 CHECKING THE BEARING 5 65 CHECKING THE OIL PUMP DRIVE GEAR 5 65 INSTALLING THE CRANKSHAFT 5 65 ASSEMBL...

Page 204: ...gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head va...

Page 205: ...ENGINE INSPECTION 5 2 10 Install Center cover Refer to GENERAL CHASSIS 1 on page 4 1...

Page 206: ...s to remove Q ty Remarks 1 Muffler protector 1 2 Muffler joint bolt 1 Loosen 3 Muffler 1 4 Muffler joint 1 5 Gasket 1 6 Exhaust pipe 1 7 Gasket 1 3 2 1 5 4 6 7 New New LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 207: ...21 Rear fender flap Rear fender Bottom cover Air filter case Refer to GENERAL CHASSIS 4 on page 4 8 GENERAL CHASSIS 9 on page 4 21 and GENERAL CHASSIS 10 on page 4 23 Rear brake caliper Rear brake hos...

Page 208: ...k Refer to FUEL TANK on page 7 1 Fuel injector Refer to FUEL INJECTOR on page 7 5 Throttle body Intake manifold Refer to THROTTLE BODY on page 7 7 1 Coolant reservoir hose 1 Disconnect 2 Coolant tempe...

Page 209: ...ut bolt front side 2 2 4 Engine mounting nut bolt rear side 2 2 5 Engine bracket 1 6 Collar 2 7 Stopper 2 8 Engine 1 2 5 1 1 6 8 7 7 6 2 3 4 4 4 3 4 3 54 Nm 5 4 m kgf 39 ft Ibf T R 28 Nm 2 8 m kgf 20...

Page 210: ...rear side 5 5 Install Engine bracket bolt nut 7 TIP Do not fully tighten the nut 6 Install Rear shock absorber assemblies 8 7 Tighten Engine bracket nut 7 TIP Before tightening the engine bracket nut...

Page 211: ...nuts TIP Tighten each nut to specification in the order of exhaust pipe nut 1 exhaust pipe nut 2 exhaust pipe nut 1 5 Tighten Muffler bolts 6 Tighten Muffler joint bolt TIP When tightening the muffler...

Page 212: ...fer to THERMOSTAT on page 6 5 Fuel injector Refer to FUEL INJECTOR on page 7 5 Intake manifold Refer to THROTTLE BODY on page 7 7 1 Spark plug cap 1 Disconnect 2 Spark plug 1 10 Nm 1 0 m kgf 7 2 ft Ib...

Page 213: ...ylinder head cover 1 7 Cylinder head cover gasket 1 8 Dowel pin 1 9 Cylinder head cover breather plate 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 N...

Page 214: ...1 15 Camshaft stopper plate 1 16 Cylinder head 1 17 Cylinder head gasket 1 18 Dowel pin 2 19 Oil nozzle 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7...

Page 215: ...lt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket 2 TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cam...

Page 216: ...pattern TIP To ensure an even surface rotate the cylinder head several times EAS31232 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket...

Page 217: ...wise b Align the I mark a on the AC magneto rotor with the match mark b on the right crank case c Install the timing chain 1 onto the camshaft sprocket 2 then the camshaft sprocket onto the camshaft a...

Page 218: ...truding from the rear left side of the timing chain ten sioner Apply sealant to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin scre...

Page 219: ...to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to...

Page 220: ...Remarks Cylinder head Refer to CYLINDER HEAD on page 5 9 1 Locknut 2 2 Adjusting screw 2 3 Rocker arm shaft 2 4 Collar 2 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Camshaft 1 8 Bearing 1 7 Nm 0 7...

Page 221: ...sed air EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Rocker arm roller 1 Damage wear Repla...

Page 222: ...r arm inside diameter Out of specification Replace the defective part s EAS30270 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install Bearing 1 onto the cylinder head TIP Install the bearing so that the...

Page 223: ...ts 4 Install Rocker arms Rocker arm shafts TIP Make sure the rocker arm shafts intake and ex haust are completely pushed into the cylinder head Recommended lubricant Rocker arm roller Molybdenum disul...

Page 224: ...ove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 9 Rocker arms Camshaft Refer to CAMSHAFT on page 5 17 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exh...

Page 225: ...he valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4...

Page 226: ...roper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 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...

Page 227: ...wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c...

Page 228: ...face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat wid...

Page 229: ...with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its origin...

Page 230: ...achment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve Valve sp...

Page 231: ...d Refer to CYLINDER HEAD on page 5 9 Water pump outlet pipe Refer to WATER PUMP on page 6 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Pis...

Page 232: ...pen the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or rep...

Page 233: ...ification 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 2 Install Piston...

Page 234: ...IN GUIDE EXHAUST SIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS30294 INSTALLING THE PISTON AND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Upper oil ring rail 3...

Page 235: ...e crankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While holding the piston with one...

Page 236: ...nd GENERAL CHASSIS 10 on page 4 23 1 V belt case air filter element cover 1 2 V belt case air filter element support 1 3 V belt case air filter element 1 4 Lower V belt case cover 1 5 V belt case air...

Page 237: ...re in stalling a new V belt case gasket remove the V belt Refer to Removing the V belt primary sheave and secondary sheave 8 Dowel pin 2 9 V belt case plate 1 10 V belt case bearing retainer 2 11 Bear...

Page 238: ...ply Shell Sunlight Grease 3 Order Job Parts to remove Q ty Remarks 1 Primary fixed sheave nut 1 2 Conical spring washer 1 3 One way clutch 1 4 Primary fixed sheave 1 5 V belt 1 6 Collar 1 7 Primary sl...

Page 239: ...y Shell Sunlight Grease 3 Order Job Parts to remove Q ty Remarks 9 Slider 3 10 Primary sheave weight 6 11 Oil seal 2 12 Collar 1 13 Clutch housing nut 1 14 Spacer 1 15 Clutch housing 1 16 Secondary sh...

Page 240: ...grease R Order Job Parts to remove Q ty Remarks 1 Secondary sheave nut 1 2 Clip 3 3 Clutch carrier plate 1 4 Clutch shoe spring 3 5 Clutch shoe 3 6 Damper 3 7 Clutch carrier 1 8 Compression spring 1...

Page 241: ...ell dolium grease R Order Job Parts to remove Q ty Remarks 10 Guide pin 3 11 Secondary sliding sheave 1 12 O ring 2 13 Oil seal 2 14 Bearing 1 15 Circlip 1 16 Bearing 1 17 Secondary fixed sheave 1 75...

Page 242: ...not remove the secondary sheave nut at this stage TIP While holding the secondary sheave with the sheave holder 2 loosen the secondary sheave nut one full turn with the locknut wrench 3 EAS30312 DISA...

Page 243: ...a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS30315 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean t...

Page 244: ...and sliding sheaves as a set 3 Check Guide pin 2 Damage wear Replace the secondary fixed and sliding sheaves as a set 4 Check Spring free length Out of specification Replace the spring EAS30320 ASSEM...

Page 245: ...ded lubricant 5 Install Spring seat Compression spring Clutch carrier 1 Secondary sheave nut 2 TIP While compressing the compression spring with the clutch spring holder 3 install the sec ondary sheav...

Page 246: ...heave weights from falling out of the primary sliding sheave 4 Install V belt 1 NOTICE ECA21720 Do not allow grease to come in contact with the V belt TIP Install the V belt with the printed arrow mar...

Page 247: ...primary fixed sheave nut EAS31235 INSTALLING THE V BELT CASE 1 Install V belt case air duct 1 TIP Be sure to fit the projection a on the V belt case air duct between the projections b on the V belt ca...

Page 248: ...V BELT AUTOMATIC TRANSMISSION 5 45 a 1 2...

Page 249: ...OIL on page 3 19 Cylinder head Refer to CYLINDER HEAD on page 5 9 Primary sliding sheave Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 1 Starter clutch cover 1 2 Oil seal 1 3 Dowel pin 2 LT E...

Page 250: ...le gear shaft 1 6 Starter clutch 1 7 Collar 1 8 Starter wheel 1 9 Bearing 1 10 Timing chain guide stopper 1 11 Timing chain 1 12 Timing chain guide intake side 1 LT E 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Page 251: ...arter wheel counterclock wise A the starter clutch and the starter wheel should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel clockwise B it shoul...

Page 252: ...R on page 6 1 1 Crankshaft position sensor coupler Stator coil assembly coupler 1 1 Disconnect 2 AC magneto rotor 1 3 Woodruff key 1 4 Crankshaft position sensor holder 1 5 Crankshaft position sensor...

Page 253: ...Install Crankshaft position sensor 1 Crankshaft position sensor holder 2 TIP Pass the stator coil assembly lead 3 under the crankshaft position sensor holder 2 Install Woodruff key AC magneto rotor Wa...

Page 254: ...C MAGNETO 5 51 TIP While holding the AC magneto rotor 2 with the rotor holding tool 3 tighten the AC magneto ro tor nut Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 1 3 2...

Page 255: ...Refer to GENERAL CHASSIS 4 on page 4 8 1 Starter motor lead 1 Disconnect 2 Engine ground lead 1 Disconnect 3 Rear brake hose holder 1 4 Negative battery lead 1 Disconnect 5 Starter motor 1 10 Nm 1 0...

Page 256: ...r motor front cover 1 3 Washer 1 4 O ring 1 5 Brush 1 6 Brush spring 2 7 Bearing 1 8 Oil seal 1 9 Armature assembly 1 10 Circlip 1 11 Stator 1 12 O ring 1 13 Starter motor rear cover 1 1 5 Nm 0 15 m k...

Page 257: ...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...

Page 258: ...e the defective part s EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor cover bolts 1 TIP Align the match mark a on the stator with the match mark b on the front and rear cover Brush spri...

Page 259: ...r cover 1 2 Spring 1 3 Oil strainer 1 4 Oil pump assembly 1 5 Oil pump assembly gasket 1 6 Oil pump housing cover 1 7 Pin 1 8 Oil pump driven gear 1 9 Oil pump inner rotor 1 10 Oil pump outer rotor 1...

Page 260: ...defective part s EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft 2 Install Oil pump driven gear Oil pump housing 1 Oil pump outer rotor 2 Oil pump inner rotor 3 Pin...

Page 261: ...ge 4 32 Transmission oil Drain Refer to CHANGING THE FINAL TRANS MISSION OIL on page 3 22 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 1 Transmission case cover 1 2 O...

Page 262: ...ve Q ty Remarks 5 Primary drive gear 1 6 Bearing 2 7 1st wheel gear 1 8 Drive axle 1 9 Oil seal 1 10 Bearing 2 11 Main axle 1 12 Primary driven gear 1 13 Bearing 2 9 8 10 10 13 6 5 6 12 11 13 8 7 New...

Page 263: ...ve wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s EAS30438 INSTALLING THE TRANSMISSION 1 Install Oil se...

Page 264: ...TRANSMISSION 5 61 TIP Tighten the transmission case cover bolts in the proper tightening sequence as shown 1 8 7 6 1 5 4 3 10 2 9...

Page 265: ...n Refer to CYLINDER AND PISTON on page 5 28 Primary sheave Secondary sheave Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 33 Starter clutch Refer to STARTER CLUTCH on page 5 46 Oil pump assembly R...

Page 266: ...oil filler cap 1 2 Dipstick 1 3 Spring 2 4 Centerstand 1 5 Left crankcase 1 6 Dowel pin 2 7 Spacer 1 8 Crankshaft assembly 1 9 Oil pump drive gear 1 10 Bearing 1 11 Right crankcase 1 11 Nm 1 1 m kgf 8...

Page 267: ...mbly 1 TIP Remove the crankshaft assembly with the crankcase separating tool 2 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA20630 To protect the end...

Page 268: ...ugh movement Replace EAS31245 CHECKING THE OIL PUMP DRIVE GEAR 1 Check Oil pump drive gear Damage wear Replace EAS30791 INSTALLING THE CRANKSHAFT 1 Install Crankshaft assembly 1 TIP Install the cranks...

Page 269: ...ome into contact with the oil gallery 3 Install Crankcase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pattern EAS31247 INSTALLING THE CENTERSTAND 1 Install Centerstand Springs...

Page 270: ...CRANKSHAFT 5 67...

Page 271: ...INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 5 CHECKING THE THERMOSTAT ASSEMBLY 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEM...

Page 272: ...S 9 on page 4 21 1 Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator cover 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7...

Page 273: ...amper 5 11 Ignition coil connector 2 Disconnect 12 Ignition coil 1 13 Radiator fan case 1 14 Radiator fan 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Page 274: ...e there is no drop in pressure 4 Check Radiator fan Damage Replace EAS30440 INSTALLING THE RADIATOR 1 Install Radiator fan case 1 TIP Tighten the radiator fan case bolts in the proper tightening seque...

Page 275: ...si of pres sure c Measure the pressure to check its maintain ing applied pressure 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RA...

Page 276: ...marks Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Center cover Refer to GENERAL CHASSIS 1 on page 4 1 1 Coolant temperature sensor coupler 1 Disconnect 2 Cooling system air bleed hose 1 D...

Page 277: ...hole lower line a at 95 C 203 F TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling EAS30445 INSTALLING THE THERMOSTAT ASSE...

Page 278: ...E ENGINE OIL on page 3 19 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 AC magneto rotor Stator coil assembly Refer to AC MAGNETO on page 5 49 1 Water pump outlet pipe 1 2 Water pump outlet...

Page 279: ...Dowel pin 1 5 Water pump housing 1 6 Dowel pin 1 7 Circlip 1 8 Washer 2 9 Impeller shaft gear 1 10 Pin 1 11 Impeller shaft 1 12 Water pump seal 1 13 Oil seal 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1...

Page 280: ...pecified depth as shown in the illustra tion 3 Lubricate Water pump seal 4 Install Impeller shaft 1 Pin 2 TIP After installing the impeller shaft add approxi mately 0 5 cm3 0 017 US oz 0 018 Imp oz of...

Page 281: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3...

Page 282: ...WATER PUMP 6 11...

Page 283: ...STALLING THE FUEL TANK 7 2 CHECKING THE FUEL PRESSURE 7 3 FUEL INJECTOR 7 5 REMOVING THE FUEL HOSE 7 6 CHECKING THE FUEL INJECTOR 7 6 ASSEMBLING THE FUEL INJECTOR 7 6 INSTALLING THE FUEL HOSE 7 6 THRO...

Page 284: ...n page 4 3 and GENERAL CHASSIS 3 on page 4 5 1 Fuel tank cap 1 2 Fuel pump coupler 1 Disconnect 3 Fuel sender coupler 1 Disconnect 4 Fuel hose connector cover 1 5 Fuel hose 1 Disconnect 6 Fuel pump br...

Page 285: ...emoved 5 Remove Fuel tank EAS30451 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 EAS304...

Page 286: ...fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA21750 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools Although the fuel has been...

Page 287: ...FUEL TANK 7 4 Refer to INSTALLING THE FUEL TANK on page 7 2...

Page 288: ...e Q ty Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Fuel injector coupler 1 Disconnect 2 Fuel hose holder 1 3 Fuel hose 1 4 Fuel injector 1 5 Fuel injector adaptor 1 6 Fuel injector joint gasket...

Page 289: ...ruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 7 6 EAS31252 ASSEMBLING THE FUEL INJE...

Page 290: ...Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Breather hose throttle body to cylinder 1 4 Throttle cable 2 Disconnect 5 Throttle cable holder 1 6 Air filter case joint clamp screw 1 Lo...

Page 291: ...1 Loosen 8 Throttle body 1 9 ISC idle speed control unit holder 1 10 ISC idle speed control unit 1 11 Spring 1 12 Intake manifold 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0...

Page 292: ...21770 Do not adjust the stop screw 1 EAS31254 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 1 Remove the throttle body from the vehicle 2 Remove Screw 1 Plate 2 ISC idle speed control uni...

Page 293: ...ny areas other than the areas a b and c If the cleaning agent en ters the ISC unit or throttle body thorough ly wipe it off 7 Adjust the ISC unit plunger to the specified distance a from the motor ass...

Page 294: ...that the rear wheel is elevated 14 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed Within specifi cation Service is finished Out of specification Repla...

Page 295: ...Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30980 INSTALLING THE THROTTLE BODY 1 Install Throttle body Throttle body joint clamp screw TIP Align the p...

Page 296: ...THROTTLE BODY 7 13...

Page 297: ...ESHOOTING METHOD 8 28 YAMAHA DIAGNOSTIC TOOL 8 29 TROUBLESHOOTING DETAILS 8 30 ELECTRICAL COMPONENTS 8 53 CHECKING THE SWITCHES 8 55 CHECKING THE BULBS AND BULB SOCKETS 8 58 CHECKING THE FUSES 8 59 RE...

Page 298: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...

Page 299: ...ion sensor 4 Main switch 6 Signaling system fuse 8 Battery 9 Negative battery lead connector 10 Main fuse 13 Sidestand switch 22 ECU engine control unit 23 Ignition coil 24 Spark plug 28 Engine ground...

Page 300: ...AND CHARGING THE BATTERY on page 8 60 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug...

Page 301: ...tand switch 9 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 65 Replace the lean angle sensor 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page...

Page 302: ...ELECTRIC STARTING SYSTEM 8 5 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...

Page 303: ...fuse 8 Battery 9 Negative battery lead connector 10 Main fuse 11 Starter relay 12 Starter motor 13 Sidestand switch 14 Starting circuit cut off relay 15 Handlebar switch Right 16 Front brake light swi...

Page 304: ...d 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 stays...

Page 305: ...an the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 65 Starter motor is OK Perform the electric starti...

Page 306: ...h front and rear Refer to CHECKING THE SWITCHES on page 8 55 Replace the brake light switch 10 Check the start switch Refer to CHECKING THE SWITCHES on page 8 55 The start switch is faulty Replace the...

Page 307: ...ELECTRIC STARTING SYSTEM 8 10...

Page 308: ...CHARGING SYSTEM 8 11 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM...

Page 309: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 8 Battery 9 Negative battery lead connector 10 Main fuse 60 Frame ground...

Page 310: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 60 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 66 Replace the st...

Page 311: ...CHARGING SYSTEM 8 14...

Page 312: ...LIGHTING SYSTEM 8 15 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM...

Page 313: ...ector 10 Main fuse 22 ECU engine control unit 28 Engine ground 34 Meter assembly 35 Multifunction meter 36 Meter light 39 High beam indicator light 42 Tail brake light assembly 45 Tail brake light 47...

Page 314: ...SOCKETS on page 8 58 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight signaling system and backup Refer to CHECKING THE FUS ES on page 8 59 Replace the fuse s 3 Check the battery...

Page 315: ...k the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or replace the wire har ness Replace the ECU meter assembly or headlight assembly Refer to RE PLACING THE ECU...

Page 316: ...SIGNALING SYSTEM 8 19 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM...

Page 317: ...ssembly 35 Multifunction meter 37 Turn signal indicator light Left 38 Coolant temperature warning light 41 Turn signal indicator light Right 42 Tail brake light assembly 43 Rear turn signal light Left...

Page 318: ...ain headlight signaling system and backup Refer to CHECKING THE FUS ES on page 8 59 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 Clean the battery ter...

Page 319: ...ight switch Refer to CHECKING THE SWITCHES on page 8 55 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 55 Replace the rear brake ligh...

Page 320: ...t assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly or ECU Refer to REPLACING THE ECU e...

Page 321: ...SIGNALING SYSTEM 8 24 NG OK 2 Check the entire speed sensor wir ing Properly connect or replace the wire har ness Replace the meter assembly...

Page 322: ...FUEL INJECTION SYSTEM 8 25 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM...

Page 323: ...temperature sensor 19 Intake air pressure sensor 20 Intake air temperature sensor 21 Throttle position sensor 22 ECU engine control unit 23 Ignition coil 24 Spark plug 25 Fuel injector 26 Fuel pump 28...

Page 324: ...trouble warning light will display the lowest error code or it will be displayed on the Yamaha diagnostic tool which remains stored in ECU memory until deleted Engine trouble warning light fault code...

Page 325: ...rouble warning light comes on 1 Check Fault code number a Check the fault code number displayed on the multi function meter right display b Identify the faulty system with the fault code number c Iden...

Page 326: ...puter The displayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool However the diagnostic tool cannot be used to freely change...

Page 327: ...o work nor mally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 Fault code No 12 1 F...

Page 328: ...ace the sensor Refer to AC MAGNETO on page 5 49 Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sen...

Page 329: ...tch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for looseness or pinch ing Im...

Page 330: ...d Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure Procedure Extend the sidestand and then operate the throttle while pus...

Page 331: ...tem Intake air pressure sensor system malfunction clogged or de tached Fault code No 15 Item Throttle position sensor open or short circuit detected Fail safe system Able to start engine Able to drive...

Page 332: ...ot dis played Service is finished Fault code number is displayed Go to item 5 5 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When th...

Page 333: ...f the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 20 Tool display Sidestand switch ON sidestand retracted OFF sidestand extended Procedure Extend...

Page 334: ...CU is detected Fault code No 21 Item Coolant temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 06 Tool display Displays t...

Page 335: ...e No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Check the coolant temperature sensor Replace th...

Page 336: ...ck blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for...

Page 337: ...pler securely or re place the wire harness Start the engine warm it up and then race it Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Wire harne...

Page 338: ...lace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 65 Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code num...

Page 339: ...passages for air leaks Start and idle the engine for ap proximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item A 5 A 5 The air volume...

Page 340: ...B 8 ISC valve operation sound is not heard Go to item B 4 B 4 Installed condition of ISC valve Check the mounting area for looseness or pinching Make sure that the installation position is correct Che...

Page 341: ...ace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 67 Execute the diagnostic mode Code Nos 36 No operating sound Go to item 3 Operating sound Go to item 6 3 Connection of wire...

Page 342: ...and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON then to OFF and...

Page 343: ...re place the wire harness Rotate the left front wheel by hand Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or shor...

Page 344: ...r this adjustment is made turn the main switch to OFF Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Repeat item 1 If the same number...

Page 345: ...back fully opens This operation takes approximately 3 seconds Procedure Check that ISC valve is actuated by listening for the operating sound Item Probable cause of malfunc tion and check Maintenance...

Page 346: ...when the Engine is idling Deceleration is poor when the vehicle is ridden Bad condition of engine or sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 03 01 Met...

Page 347: ...Check for looseness or pinch ing Start the engine and let it idle for approximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 7 7 De...

Page 348: ...r is displayed Go to item 9 9 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 59 Start the engine and let it idle for approximately 10 seconds Fault code nu...

Page 349: ...FUEL INJECTION SYSTEM 8 52...

Page 350: ...ELECTRICAL COMPONENTS 8 53 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 6 9 11 12 10 8 7 13 17 18 19 23 22 21 20 14 15 16...

Page 351: ...relay 9 Starting circuit cut off relay 10 Headlight relay 11 ECU engine control unit 12 Rectifier regulator 13 ISC idle speed control unit 14 Throttle position sensor 15 Intake air pressure sensor 16...

Page 352: ...ELECTRICAL COMPONENTS 8 55 EAS30549 CHECKING THE SWITCHES ON R Br OFF B P G Y L B Ch Dg Br W B L G R Br L G L Y G Y B Dg P Ch Br W L B B L Y G Y L Y B L Y B B 1 2 3 4 5 6 7 8...

Page 353: ...ELECTRICAL COMPONENTS 8 56 1 Front brake light switch 2 Start switch 3 Horn switch 4 Dimmer switch 5 Turn signal switch 6 Rear brake light switch 7 Main switch 8 Sidestand switch...

Page 354: ...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...

Page 355: ...bulbs 1 Remove Bulb WARNING EWA17540 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA14381 Be sure to hold the socke...

Page 356: ...e 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...

Page 357: ...RLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If t...

Page 358: ...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 bat...

Page 359: ...t voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is hig...

Page 360: ...ation Replace a Remove the ignition coil from the spark plug b Connect the pocket tester 1 to the igni tion coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery t...

Page 361: ...witch to ON d Measure the ignition spark gap a e Crank the engine by pushing the of the start switch and gradually increase the spark gap until a misfire occurs EAS30560 CHECKING THE CRANKSHAFT POSITI...

Page 362: ...leshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 8 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a j...

Page 363: ...THE FUEL SENDER 1 Remove Fuel pump from the fuel tank 2 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester 10 100 to the fuel sender terminals...

Page 364: ...h coolant 2 TIP Make sure that the coolant temperature sensor terminals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Mea...

Page 365: ...ELECTRICAL COMPONENTS 8 68 c Measure the fuel injector resistance Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 2 1...

Page 366: ...ELECTRICAL COMPONENTS 8 69...

Page 367: ...9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE T...

Page 368: ...d or damaged fuel hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty batte...

Page 369: ...loose or worn clutch shoe spring 2 Clutch shoe s Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt Slipping V belt Oil or grease on...

Page 370: ...amaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head component...

Page 371: ...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 swit...

Page 372: ...when the engine is idling 39 Injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Speed sensor no normal signals are received from the speed sensor 44 EEPROM...

Page 373: ...the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sen sor and incline it more than 50 degrees Upright 0 4 1 4 Overturned 3 7 4 4 09 Fuel system voltage...

Page 374: ...ontrol number 0 254 Diagnostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals Illuminates the engine trou ble warning light Check that...

Page 375: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 8...

Page 376: ...beam indicator light 40 Engine trouble warning light 41 Turn signal indicator light Right 42 Tail brake light assembly 43 Rear turn signal light left 44 Rear turn signal light Right 45 Tail brake lig...

Page 377: ......

Page 378: ......

Page 379: ...MW125 2014 MW125F 2015 WIRING DIAGRAM MW125 2014 MW125F 2015 SCH MA DE C BLAGE MW125 2014 MW125F 2015 SCHALTPLAN MW125 2014 MW125F 2015 SCHEMA ELETTRICO MW125 2014 MW125F 2015 DIAGRAMA EL CTRICO...

Page 380: ...MW125 2014 MW125F 2015 WIRING DIAGRAM MW125 2014 MW125F 2015 SCH MA DE C BLAGE MW125 2014 MW125F 2015 SCHALTPLAN MW125 2014 MW125F 2015 SCHEMA ELETTRICO MW125 2014 MW125F 2015 DIAGRAMA EL CTRICO...

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