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Yamaha Raptor 700R 2009, Service Manual

The Yamaha Raptor 700R 2009 Service Manual is a comprehensive guide for owners and enthusiasts of this powerful ATV. Packed with detailed instructions, illustrations, and specifications, this manual is available for free download from our manualshive.com, ensuring you have all the necessary information to maintain and repair your Raptor 700R.

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REAR AXLE AND REAR AXLE HUB

4-12

EAS29470

REAR AXLE AND REAR AXLE HUB

Removing the rear axle and rear axle hub

Order

Job/Parts to remove

Q’ty

Remarks

Rear wheels/rear wheel hubs

Refer to “REAR WHEELS” on page 4-9.

1

Set bolt

2

2

Rear axle ring nut

1

3

Conical spring washer

1

4

Rear axle pinch bolt

4

5

Rear brake caliper

1

TIP

Do not apply the brake pedal and do not use 
the parking brake when the brake caliper is 
off of the brake disc as the brake pads will 
be forced shut.

6

Brake disc/brake disc bracket

1/1

7

Rear axle

1

8

Circlip

1

9

Driven sprocket/sprocket bracket

1/1

10

Circlip

1

11

Brake caliper bracket

1

16

16

1

1

2

3

7

5

6

4

(4)

(4)

11

10

12

17

15

15

14

14

13

8

9

LT

LT

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T.R.

33 Nm (3.3 m 

•

 

kg, 24 ft

 

•

 

Ib)

T.R.

240 Nm (24.0 m 

•

 

kg, 170 ft 

•

 lb)

T.R.

34 Nm (3.4 m 

•

 

kg, 24 ft

 

•

 

Ib)

T.R.

21 Nm (2.1 m 

•

 

kg, 15 ft

 

•

 

Ib)

T.R.

72 Nm (7.2 m 

•

 kg, 52 ft 

•

 lb)

T.R.

Summary of Contents for Raptor 700R 2009

Page 1: ...2009 SERVICE MANUAL YFM70RY 1S3 28197 E2 ...

Page 2: ... YFM70RY SERVICE MANUAL 2008 by Yamaha Motor Co Ltd First edition June 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...th the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

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

Page 5: ... 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a n...

Page 6: ......

Page 7: ...EAS20110 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: ...ELF ADJUSTING PARKING BRAKE MECHANISM 1 4 PARKING BRAKE OPERATION 1 5 INSTRUMENT FUNCTIONS 1 7 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 10: ...0140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts 1 1 ...

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

Page 12: ...e injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temperature sensor and speed sensor enable the ECU to determine the injection du ration The injection timing is determined through the signals from the crankshaft position sensor ...

Page 13: ...een the brake caliper piston 7 and the adjusting bolt This adjustment procedure is unnecessary for vehicles equipped with a self adjusting parking brake mechanism The proper clearance is automatically maintained at all times ensuring stable braking per formance when parking the vehicle 1 2 3 4 5 6 7 1 Parking brake arm 2 Parking brake shaft 3 Adjusting bolt 4 Adjusting bolt sleeve 5 Adjusting bolt...

Page 14: ...e receives the force the dark shaded area in the above illustration is pushed and the brake pad 6 is pushed against the brake disc When the brake pad wears the clearance between the brake caliper piston 5 and the brake pad be comes larger and the force applied to the brake pad becomes weaker If this occurs the self adjusting parking brake mechanism adjusts automatically to achieve the proper clear...

Page 15: ...pedal is operated the brake fluid pressure increases and the brake caliper piston and the nut move 2 When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt the force A will be required to pull the adjusting bolt The force to pull the adjusting bolt will be turned into the rotation torque B by the shape of the threads ...

Page 16: ...etween mph and km h Clock mode Pushing the CLOCK button for at least three seconds to switch the display between the clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the SELECT button and RESET but ton together for at least three seconds 3 When the hour digits start flashing push the RESET button to se...

Page 17: ... 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 18: ...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 19: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 20: ...vided 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 5 38 8 59 8 60 8 61 8 65 8 66 8 67 8 68 8 69 8 70 8 71 8 72 8 73 8 74 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 3 5 Tim...

Page 21: ...6 mm 90890 01498 Rear axle nut wrench 46 mm YM 37134 4 14 4 15 Damper rod holder 30 mm 90890 01327 YM 01327 4 46 Ball joint remover 90890 01474 YM 01474 4 52 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480 4 52 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 15 5 17 Tool name Tool No Illustration Reference pages ...

Page 22: ...243 Valve spring compressor adapter 26 mm YM 01253 1 5 20 5 25 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 21 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 21 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 21 Tool name Tool No Illustration Reference pages YU 01083 3 ...

Page 23: ...7 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 33 5 35 Flywheel puller 90890 01404 YM 01404 5 33 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 35 5 60 Universal clutch holder 90890 04086 YM 91042 5 44 5 48 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 24: ...ft installer pot 90890 01274 Installing pot YU 90058 5 63 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 63 Adapter M16 90890 04130 Adapter 13 YM 04059 5 63 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 63 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ...

Page 25: ...ap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 2 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 7 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 7 Pressure gauge 90890 03153 YU 03153 7 7 Tool name Tool No Illustration Reference pages ø35 YU 24460 01 YU 33984 ...

Page 26: ...adapter 90890 03176 YM 03176 7 7 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 8 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 68 Tool name Tool No Illustration Reference pages ...

Page 27: ...ENING TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 41 ...

Page 28: ...3W For Oceania Dimensions Overall length 1845 mm 72 6 in Overall width 1170 mm 46 1 in Overall height 1130 mm 44 5 in Seat height 815 mm 32 1 in Wheelbase 1280 mm 50 4 in Ground clearance 240 mm 9 4 in Minimum turning radius 3500 mm 138 in Weight With oil and fuel 192 0 kg 423 lb Maximum loading limit 100 0 kg 220 lb ...

Page 29: ... 30 or SAE 10W 40 or SAE 15W 40 or SAE 20W 40 or SAE 20W 50 For Europe and Oceania Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 2 30 L 2 43 US qt 2 02 Imp qt Without oil filter element replacement 1 75 L 1 85 US qt 1 54 Imp qt With oil filter element replacement 1 85 L 1 96 US qt 1 63 Imp qt Oil pressure hot 40 0 kPa 1600 r min 0 40 k...

Page 30: ...suction centrifugal pump Reduction ratio 27 28 0 964 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug Manufacturer model NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 59 1 60 5 cm 3 61 3 69 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 43 300 43 400 mm 1 7047 1 7087 in Limit 43 200 mm 1 7008 in Intake B ...

Page 31: ...ns Valve head diameter A intake 37 90 38 10 mm 1 4921 1 5000 in Valve head diameter A exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve face width B intake 2 26 mm 0 0890 in Valve face width B exhaust 2 26 mm 0 0890 in Valve seat width C intake 1 00 1 20 mm 0 0394 0 0472 in Limit 1 6 mm 0 063 in Valve seat width C exhaust 1 00 1 20 mm 0 0394 0 0472 in Limit 1 6 mm 0 063 in Valve margin thickness D int...

Page 32: ...ee length intake 38 79 mm 1 53 in Limit 36 85 mm 1 45 in Free length exhaust 38 79 mm 1 53 in Limit 36 85 mm 1 45 in Installed length intake 35 00 mm 1 38 in Installed length exhaust 35 00 mm 1 38 in Spring rate K1 intake 48 55 N mm 4 95 kgf 277 22 lbf Spring rate K2 intake 63 02 N mm 6 43 kgf 359 84 lbf Spring rate K1 exhaust 48 55 N mm 4 95 kgf 277 22 lbf Spring rate K2 exhaust 63 02 N mm 6 43 k...

Page 33: ...1 mm 0 9044 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in Piston ring Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 20 0 35 mm 0 008 0 014 in Limit 0 60 mm 0 024 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 05 0 16 i...

Page 34: ...mm 0 20 0 39 in Friction plate 1 thickness 2 92 3 08 mm 0 11 0 12 in Wear limit 2 82 mm 0 111 in Plate quantity 7 pcs Friction plate 2 thickness 2 90 3 10 mm 0 11 0 12 in Wear limit 2 8 mm 0 11 in Plate quantity 1 pc Clutch plate thickness 1 50 1 60 mm 0 059 0 063 in Plate quantity 7 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring free length 50 0 mm 1 97 in Minimum length 48 0 mm 1 89 in Spring...

Page 35: ...ment Air filter oil grade Foam air filter oil Fuel pump Pump type Electrical Model manufacturer 1S3 DENSO Maximum consumption amperage 4 8 A Output pressure 324 kPa 3 24 kg cm 46 1 psi Throttle body Type quantity 44EHS 1 Manufacturer MIKUNI ID mark 1S3H 10 Throttle valve size 50 Fuel injector Model quantity 297500 0390 1 Manufacturer DENSO Idling condition Engine idling speed 1500 1700 r min Intak...

Page 36: ...runout limit 2 0 mm 0 08 in Rear wheel Wheel type Panel wheel Rim size 9 8 0AT Rim material Aluminum Wheel travel 256 mm 10 1 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Front tire Type Tubeless Size AT21 7R10 Manufacturer model DUNLOP KT341 Radial Wear limit front 3 mm 0 12 in Rear tire Type Tubeless Size AT20 10R9 Manufacturer model DUNLOP KT345 Radial W...

Page 37: ... disc thickness limit 3 0 mm 0 12 in Brake disc deflection limit 0 15 mm 0 006 in Brake pad lining thickness inner 5 3 mm 0 21 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 5 3 mm 0 21 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 32 03 mm 1 26 in Recommended fluid DOT 4 Steering Steering bearing type Ball and race bearing Fron...

Page 38: ... Spring stroke K1 0 0 110 0 mm 0 00 4 33 in Optional spring available No Spring preload adjusting positions Minimum 228 0 mm 8 98 in Standard 233 0 mm 9 17 in Maximum 243 0 mm 9 57 in Rebound damping adjusting positions Minimum 20 Standard 13 Maximum 3 Compression damping setting for fast compression damping Minimum 4 Standard 2 Maximum 0 Compression damping setting for slow compression damping Mi...

Page 39: ... 80 C 176 F Ignition coil Model manufacturer JO267 DENSO Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 3 40 4 60 Ω at 20 C 68 F Secondary coil resistance 10 40 15 60 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ at 20 C 68 F AC magneto Model manufacturer LMX58 DENSO Standard output 14 0 V 17 2 A at 5000 r min Stator coil resistance 0 248 0 372 Ω at 20 C 68 F ...

Page 40: ... 00 mm 0 20 in Brush spring force 7 65 10 01 N 780 1021 gf 27 54 36 03 oz Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768106 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω at 20 C 68 F Fan motor relay Model manufacturer ACM33211 M05 MATSUSHITA Starting circuit cut off relay Model manufacturer G8R 30Y V3 OMRO...

Page 41: ...ELECTRICAL SPECIFICATIONS 2 14 Ignition fuse 10 0 A Fuel injection system fuse 10 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A ...

Page 42: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 43: ...cket joint bolt M6 2 10 Nm 1 m kg 7 2 ft lb AC magneto rotor nut M16 1 60 Nm 6 m kg 43 ft lb AC magneto cover bolt M6 14 10 Nm 1 m kg 7 2 ft lb Balancer driven gear nut M16 2 60 Nm 6 m kg 43 ft lb Use a lock washer Breather plate bolt M6 3 10 Nm 1 m kg 7 2 ft lb Primary drive gear nut M20 1 110 Nm 11 m kg 80 ft lb Use a lock washer Valve adjusting screw nut M6 4 14 Nm 1 4 m kg 10 ft lb Camshaft be...

Page 44: ...1 m kg 7 2 ft lb Intake manifold clamp screw M4 2 3 Nm 0 3 m kg 2 2 ft lb Air filter case joint clamp screw M5 1 4 Nm 0 4 m kg 2 9 ft lb ECU bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Exhaust pipe 2 and exhaust pipe 1 bolt M8 1 16 Nm 1 6 m kg 11 ft lb Spark arrester bolt M6 1 8 Nm 0 8 m kg 5 8 ft lb Muffler and exhaust pipe 2 bolt M8 1 18 Nm 1 8 m kg 13 ft lb Muffler bolt M8 2 38 Nm 3 8 m kg 27 ft ...

Page 45: ...ft lb Shift drum segment bolt M8 1 30 Nm 3 m kg 22 ft lb Shift guide bolt M6 2 10 Nm 1 m kg 7 2 ft lb Reverse shift lever bolt M6 1 13 Nm 1 3 m kg 9 4 ft lb Shift pedal bolt M6 1 16 Nm 1 6 m kg 11 ft lb Stator coil bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Crankshaft position sensor bolt M5 2 7 Nm 0 7 m kg 5 1 ft lb AC magneto lead holder bolt M5 1 7 Nm 0 7 m kg 5 1 ft lb Coolant temperature sensor M12 1 ...

Page 46: ...elay arm nut lower M10 1 43 Nm 4 3 m kg 31 ft lb Rear axle pinch bolt M8 4 21 Nm 2 1 m kg 15 ft lb Rear axle guide bolt M12 1 55 Nm 5 5 m kg 40 ft lb Swingarm skid plate bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Drive chain guide bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Drive sprocket cover bolt M6 2 10 Nm 1 m kg 7 2 ft lb Upper front arm nut M10 2 38 Nm 3 8 m kg 27 ft lb Lower front arm nut M10 4 55 Nm 5 5 m kg...

Page 47: ...pivot bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Front brake master cylinder union bolt M10 1 27 Nm 2 7 m kg 19 ft lb Throttle lever assembly holder bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Clutch lever holder bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Parking brake lever mounting bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake pipe nut M10 1 19 Nm 1 9 m kg 13 ft lb Brake hose joint bolt M6 1 10 Nm 1 m kg 7 2 ft lb Brake ho...

Page 48: ...aster cylinder ad justing bolt M8 1 17 Nm 1 7 m kg 12 ft lb Parking brake adjusting bolt M6 1 10 Nm 1 m kg 7 2 ft lb Rear brake disc mounting bolt M8 4 33 Nm 3 3 m kg 24 ft lb Brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front guard bolt M8 4 12 Nm 1 2 m kg 8 7 ft lb Front fender bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front fender nut M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight bolt M6 4 7 Nm 0 7 m k...

Page 49: ...essor lever pin Decompressor lever spring Water pump impeller shaft Oil pump rotors inner rotor 2 and outer rotor 2 and pump Oil pump rotors inner rotor 1 and outer rotor 1 and pump Torque limiter Starter idle gear and starter wheel gear inner surface Primary driven gear Clutch pull rod Transmission gears wheel and pinion Shift drum Shift forks Shift fork guide bar Shift lever assembly Shift shaft...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 10 7 6 5 4 3 1 2 17 3 13 16 15 3 14 11 12 18 8 20 19 21 9 ...

Page 51: ...kcase 5 AC magneto cover 6 Oil tank inlet hose 7 To oil tank 8 Main axle 9 Drive axle 10 Counter axle 11 From oil tank 12 Oil tank outlet hose joint 13 Clutch cover 14 Oil filter element 15 Drain bolt 16 To clutch cover 17 Crankshaft 18 Oil delivery pipe 19 Camshaft 20 Decompression 21 Cylinder head ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS 1 4 3 1 2 3 4 ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil tank breather hose 2 Oil tank outlet hose 3 Oil tank inlet hose 4 Oil tank ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 2 3 A A A A 2 1 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil delivery pipe 2 Oil filter 3 Oil pump ...

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

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter 2 Oil pump driven gear 3 Oil pump rotor 1 4 Oil pump rotor 2 5 Oil tank outlet hose joint 6 Main axle 7 Counter axle ...

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

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil strainer 2 Oil pump rotor 2 3 Oil pump rotor 1 4 Oil pump driven gear A To oil tank ...

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

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Balancer 1 2 Crankshaft ...

Page 62: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS B B A A A A B B 2 3 4 5 6 7 1 A B C D D E F G H I ...

Page 63: ...ng outward D Position the screw clamp so that its screw can be tightened from the right side of the vehicle E Install the radiator outlet hose with its white paint mark facing outward F Install the radiator outlet hose with its yellow paint mark facing outward G From fast idle plunger H Position the screw clamp so that its screw can be tightened from the right side of the vehicle Make sure that th...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 37 B A C C D D C C A D D B 6 7 1 2 3 4 5 6 1 6 2 6 3 4 A B C D E ...

Page 65: ...r fan motor breather hose through the guide B Install the coolant reservoir hose onto the radiator pipe making sure that it contacts the radiator C Pass the coolant reservoir hose and radiator fan motor breather hose through the guide on the fuel tank shield D 60 mm 2 36 in E Pass the clamp through the hole in the stay on the frame and then fasten the coolant reservoir hose and drain hose with the...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 39 A B B 4 1 1 2 2 3 A B B A A B ...

Page 67: ...er pump 3 Water pump breather hose 4 Water jacket inlet housing A From radiator B Install the water pump outlet hose onto the water jacket inlet housing making sure to align the yellow paint mark on the hose with the projection on the water jacket inlet housing ...

Page 68: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING A B 1 2 7 3 4 5 6 1 3 4 5 7 6 14 15 16 17 18 2 8 9 10 11 12 13 C D E F G H I J K L M N O ...

Page 69: ...embly lead and then fasten the hose with the holder on the fuel tank shield H Route the radiator fan motor breather hose in front of the handlebar switch lead clutch switch lead front brake light switch lead main switch lead and meter assembly lead I Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the wire harness with the band making sure...

Page 70: ...ROUTING 2 43 A D B C C E E B E E B B C C A D A B C 1 2 3 4 D E 5 6 7 7 F G H I J K L 8 9 10 11 12 13 M N O P Q 14 15 16 17 18 19 5 5 6 6 25 3 23 S T 4 24 20 20 21 22 U V 9 12 12 13 13 13 14 15 W 14 14 26 27 R ...

Page 71: ...s that branch off from the wire harness do not contact the frame J Route the lean angle sensor lead to the outside of the AC magneto lead sub wire harness rear brake light switch lead and speed sensor lead K Route the leads that branch off from the wire harness over the crankcase breather hose then towards the right side of the vehicle L Route the starter motor lead between the frame and the batte...

Page 72: ...CABLE ROUTING 2 45 A A A A 1 2 3 4 5 6 A 7 8 9 10 11 12 13 12 13 C D E F G H B ...

Page 73: ...light lead with the plastic band making sure to point the end of the band downward Fasten the leads near the tail brake light coupler and after the split in the wire harness making sure to install the plastic band around the protective sleeve of the tail brake light lead not the lead itself E Insert the projection on the wire harness holder into the hole in the frame F Fasten the wire harness with...

Page 74: ...CABLE ROUTING 2 47 B B A B B A A 8 9 10 11 A A 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 B C 21 22 D E F 23 24 25 G H I J 26 27 28 29 30 28 K 13 18 18 ...

Page 75: ...bly A Route the reverse control cable to the front of the wire harness B Route the crankcase breather hose between the battery box and the air filter joint and under the wire harness C Leave some slack in the intake air temperature sensor lead in the area shown in the illustration D Route the negative battery lead between the lean angle sensor and the wire harness E Connect the AC magneto lead sub...

Page 76: ...CABLE ROUTING 2 49 A A A A 1 2 3 4 5 6 7 8 A 9 10 11 5 4 12 ...

Page 77: ...lay 3 Fuse box 4 Relay unit 5 Relay unit lead 6 Starter motor lead 7 Starter relay lead 8 Starter relay 9 Fuse box lead 10 Headlight relay lead 11 Radiator fan motor relay lead 12 Tail brake light lead A Route the starter motor lead under the starter relay lead ...

Page 78: ...CABLE ROUTING 2 51 E E E E A B C D F F D C B A A B C 1 2 3 D 4 5 6 7 E F 8 9 9 10 11 G 12 13 13 13 13 14 14 14 14 15 16 17 18 H I J K L ...

Page 79: ... air pressure sensor D Route the spark plug lead to the outside of the clutch cable and parking brake cable making sure that the lead does not contact the cylinder head E Route the headlight lead right over the frame connect the headlight coupler and then insert the projection on the coupler into the hole in the stay on the front fender bracket F Route the reverse control cable to the inside of th...

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

Page 81: ...R FREE PLAY 3 7 ADJUSTING THE SPEED LIMITER 3 8 CHECKING THE SPARK PLUG 3 8 CHECKING THE IGNITION TIMING 3 9 MEASURING THE COMPRESSION PRESSURE 3 10 CHECKING THE ENGINE OIL LEVEL 3 11 CHANGING THE ENGINE OIL 3 12 ADJUSTING THE CLUTCH LEVER FREE PLAY 3 13 CLEANING THE AIR FILTER ELEMENT 3 14 CHECKING THE THROTTLE BODY JOINT 3 15 CHECKING THE FUEL LINE 3 15 CHECKING THE CRANKCASE BREATHER HOSE 3 15 ...

Page 82: ...THE DRIVE CHAIN SLACK 3 26 CHECKING THE STEERING SYSTEM 3 27 ADJUSTING THE TOE IN 3 27 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 28 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 29 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 3 31 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 31 CHECKING THE TIRES 3 34 CHECKING THE WHEELS 3 35 CHECKING AND LUBRICATING THE CABLES 3 35 LUBRICATING THE CLUTCH LEVE...

Page 83: ......

Page 84: ...al skills EBU21864 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichever comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and re place if necessary 2 Spark plug Check condition and clean regap or replace if nec essary 3 Valves Check valve cle...

Page 85: ...uts bolts and screws are proper ly tightened 13 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 14 Rear suspension re lay arm and connect ing arm pivoting points Check operation and correct if necessary Lubricate with lithium soap based grease 15 Steering shaft Lubricate with lithium soap based grease 16 Steering system Check opera...

Page 86: ...ODIC MAINTENANCE 3 3 Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 87: ...r 2 3 Disconnect Spark plug cap 1 4 Remove Spark plug 2 5 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the punch mark a in the camshaft sprocket with the stationary pointer b on the cylinder head c Align the TDC mark c on...

Page 88: ...ined 8 Install Timing mark accessing screw Crankshaft end accessing screw Spark plug 9 Connect Spark plug cap 10 Install O ring Camshaft sprocket cover O ring 1 Intake tappet cover O ring Exhaust tappet cover 11 Install Fuel tank Direction a Valve clearance is increased Direction b Valve clearance is decreased Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 1 1 2 3 4 a b T R Locknu...

Page 89: ...xhaust gas volume 1 Turn the main switch to OFF and set the en gine stop switch to ON 2 Simultaneously press and hold the SE LECT and RESET buttons turn the main switch to ON and continue to press the but tons for 8 seconds or more TIP All displays on the meter disappear dIAG appears on the multifunction meter 3 Press and release the SELECT button to select the CO adjustment mode Co 1 4 After sele...

Page 90: ...lide 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 lever free play is ob tained d Tighten the locknut TIP If the specified throttle lever free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the throttle lever side Throttle lever side a Slide back the rubber cover 4 b Loosen the loc...

Page 91: ...e speed limiter should be screwed in completely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation do not turn out the adjuster more than the speci fied length Also always adjust the throttle cable free play to within specification EAS20690 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 2 Re...

Page 92: ...Timing light Digital tachometer to spark plug lead 2 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Remove the timing mark accessing screw 1 c Check that the stationary pointer a on the AC magneto cover is within the firing range b on the AC magneto Incorrect firing range Check the ignition system TIP The ignitio...

Page 93: ... spark plug use com pressed air to blow away any dirt accumulat ed in the spark plug well to prevent it from falling into the cylinder c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oi...

Page 94: ...o lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP B...

Page 95: ... is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Check the O rings 3 and replace them if they are cracked or damaged c Install the new oil filter element and the oil fil ter element cover 9 Check Engine oil drain bolt gasket Damage Replace 10 Install Engine oil drain bolt crankcase along with the gasket Engine oil drain bolt...

Page 96: ...blem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification EAS1S3L043 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Handlebar side a Pull back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting bolt 3 clockwise or coun terclockwise until the specified clutch lever fre...

Page 97: ...e play is obtained c Tighten the locknut EAS20941 CLEANING THE AIR FILTER ELEMENT TIP On the bottom of the air filter case is a check hose 1 If dust or water or both collects in this hose clean the air filter element and air filter case 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Air filter case cover 1 3 Remove Wing bolt 1 Air filter element 2 Air filter element frame 3 4 Clean Ai...

Page 98: ...nstalled Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect carburetor synchronization leading to poor engine per formance and possible overheating 8 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS21020 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Cracks damage Replace EAS21030 ...

Page 99: ... performing this operation Do not start the engine when removing the tailpipe from the muffler a Remove the bolt 1 b Remove the tailpipe 2 by pulling it out of the muffler c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler T R Exhaust p...

Page 100: ...water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING...

Page 101: ...gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled 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 counter...

Page 102: ... content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Air bleed bolt 13 Install Radiat...

Page 103: ...oir cap 16 Start the engine warm it up for several min utes and then stop it 17 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 17 TIP Before checking the coolant level wait a few minutes until the coolant has settled a ...

Page 104: ...a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake ped al height is within the specified limits c Tighten the locknut WARNING EWA14900 After this adjustment is performed lift the front and rear wheels off the ground by plac ing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again EAS21240 CHECK...

Page 105: ...ake sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Remove Front wheel Refer to FRONT WHEELS on page 4 5 2 Check Front brake pad Wear indicator 1 almost touches the brake disc Replace the brake pads as a set Refer to FRONT BRAKES on page 4 17 3 Operate the brake lever 4 Install Front wheels Re...

Page 106: ... hose Refer to REAR BRAKE on page 4 28 EAS29210 ADJUSTING THE PARKING BRAKE 1 Check Parking brake cable end length a Out of specification Adjust 2 Adjust Parking brake cable end length a Pull back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified brake cable end length is obtained d Tighten the locknut e Slide the rubber cover to its origi...

Page 107: ... there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill th...

Page 108: ...ift pedal height a Loosen the bolt 1 b Remove the shift pedal 2 c Install the shift pedal at the correct height d Tighten the bolt to specification EAS29240 ADJUSTING THE REVERSE CONTROL CABLE 1 Check Reverse knob free play a Out of specification Adjust 2 Adjust Reverse knob free play a Slide back the boots 1 and 2 b Loosen the locknut 3 c Turn the adjusting nut 4 until the reverse control cable 5...

Page 109: ...ar axle pinch bolts in the proper se quence as shown b Insert an appropriate shaft 2 in the hole 4 of rear axle hub 3 so that the sprocket bracket 5 does not move c Shift the transmission into the neutral posi tion d To loosen the drive chain push the vehicle forward and to tighten the drive chain pull the vehicle backward NOTICE ECA1S3L001 Excessive chain slack will overload the en gine and other...

Page 110: ...here is no weight on the front wheels 5 Check Ball joints and wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings EAS29290 ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure Toe in Out of specification Adjust TIP Before measuring the toe in make sure that the tire pressure is correct a Mark bot...

Page 111: ...umber of turns should be given to both the right and left tie rods 2 until the specified toe in is obtained This is to keep the length of the tie rods the same d Tighten the rod end locknuts of both tie rods TIP Adjust the tie rod ends so that A and B are equal EAS29300 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Pla...

Page 112: ... wheels by placing a suitable stand under the frame b Loosen the locknut 1 c Turn the adjusting ring 2 in direction a or b TIP Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjust ment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster NOTICE ECA1S3L002 Never attempt to turn the adjusting ring be yond the maximum or minimum set...

Page 113: ...justing bolt 1 in direction a or b TIP Make sure that the position indicator marks c are aligned when the shock absorber is set to the standard setting T R Locknut 42 Nm 4 2 m kgf 30 ft lbf Direction a Rebound damping force is increased Direction b Rebound damping force is decreased Rebound damping adjusting posi tions Minimum 20 click s out Standard 12 click s out Maximum 3 click s out With the a...

Page 114: ... the rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 Gas cylinder Damage gas leaks Replace the rear shock absorber assembly Spring Fatigue Replace the rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 3 Check Operation Pump the rear shock absorber assembly up and down several times Unsmooth operation Replace rear shock absorber assemb...

Page 115: ...he steering nut wrench Always tighten the locknut against the adjust ing ring then torque it to specification 3 Install Air filter case with air intake duct 4 Adjust Rebound damping force a Turn the adjusting screw 1 in direction a or b Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen si...

Page 116: ...n indicator marks c are aligned when the shock absorber is set to the standard setting 6 Adjust Compression damping force slow compres sion damping a Turn the adjusting screw 1 in direction a or b Rebound damping adjusting posi tions Minimum 20 click s out Standard 13 click s out Maximum 3 click s out With the adjusting konb fully turned in Direction a Compression damping force is in creased Direc...

Page 117: ...aracteristics and are therefore not recommended Tire pressure WARNING EWA14960 Tire pressure below the minimum specifi cation could cause the tire to dislodge from the rim under severe riding conditions Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pressures and fast inflation may cause a tire to burst Inf...

Page 118: ...ide with a worn out tire When the tire tread reaches the wear limit a replace the tire immediately EAS29350 CHECKING THE WHEELS The following procedure applies to all of the wheels 1 Check Wheel 1 Damage bends Replace WARNING EWA14990 Never attempt even small repairs to the wheel Ride conservatively after installing a tire to allow it to seat itself properly on the rim TIP Always balance the wheel...

Page 119: ...UTCH LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS27S1002 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving p...

Page 120: ...ight 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 5 Install Headlight bulb holder Headlight bul...

Page 121: ...ELECTRICAL SYSTEM 3 38 1 a b ...

Page 122: ...ELECTRICAL SYSTEM 3 39 ...

Page 123: ... WHEELS 4 11 REAR AXLE AND REAR AXLE HUB 4 12 REMOVING THE REAR AXLE 4 14 CHECKING THE REAR AXLE 4 14 CHECKING THE REAR WHEEL SPROCKET 4 15 CHECKING THE REAR BRAKE DISC 4 15 INSTALLING THE REAR WHEEL SPROCKET 4 15 INSTALLING THE REAR AXLE 4 15 FRONT BRAKES 4 17 INTRODUCTION 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE PADS 4 23 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 23 CHEC...

Page 124: ... THE LOCK WASHER 4 46 INSTALLING THE PITMAN ARM 4 46 TIE RODS AND STEERING KNUCKLES 4 47 REMOVING THE STEERING KNUCKLES 4 48 CHECKING THE TIE RODS 4 48 CHECKING THE STEERING KNUCKLES 4 48 INSTALLING THE TIE RODS 4 48 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 49 HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES 4 51 DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY 4 51 REMOVING THE FRONT ARMS 4 51 CH...

Page 125: ...SWINGARM 4 59 REMOVING THE SWINGARM 4 61 CHECKING THE SWINGARM 4 61 INSTALLING THE SWINGARM 4 61 CHAIN DRIVE 4 63 CHECKING THE DRIVE CHAIN 4 64 INSTALLING THE DRIVE CHAIN 4 65 ...

Page 126: ...the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Left foot protector 1 4 Right foot protector 1 5 Engine skid plate 1 For installation reverse the removal proce dure 4 1 4 3 5 2 LT 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R ...

Page 127: ...ight coupler 2 Disconnect 2 Left headlight 1 3 Right headlight 1 4 Fuel tank top panel 1 5 Meter assembly coupler 1 Disconnect 6 Front fender 1 For installation reverse the removal proce dure 4 5 6 3 2 1 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft...

Page 128: ...lead 2 Disconnect NOTICE ECA1S3L009 First disconnect the negative lead then disconnect the positive lead 4 Battery 1 5 ECU electronic control unit 1 6 Intake air temperature sensor coupler 1 7 Idle air hose 1 8 Crankcase breather hose 1 9 Clamp throttle body joint 1 Loosen 10 Tail brake light lead coupler 1 Disconnect 11 Tail brake light assembly 1 2 3 3 4 3 13 8 12 5 6 10 11 7 9 4 1 7 Nm 0 7 m kg...

Page 129: ...on reverse the removal proce dure Removing the rear fender Order Job Parts to remove Q ty Remarks 2 3 3 4 3 13 8 12 5 6 10 11 7 9 4 1 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R ...

Page 130: ...t wheels Place the vehicle on a level surface 1 Front wheel 1 2 Brake disc guard outer 1 3 Cotter pin 1 4 Front wheel axle nut 1 5 Front brake caliper assembly 1 TIP Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut 6 Front wheel hub 1 7 Front brake disc 1 For installation reverse the removal proce dure ...

Page 131: ...4 and CHECKING THE WHEELS on page 3 35 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play 3 3 Check Wheel balance Out of balance Adjust WARNING EWA15000 After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident re sulting in vehicle damage and ...

Page 132: ... strike the center race or balls of the bearing Contact should be made only with the outer race EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1 Install Bearings 1 TIP Face the oil seal side of the bearing inward EAS1S3L013 INSTALLING THE FRONT BRAKE DISCS 1 Install Brake discs TIP Install the brake disc so that the recessed por tion of the bolt hole faces away from the hub EAS29410 INSTALLING T...

Page 133: ...lowing procedure applies to both of the front wheels 1 Install Brake disc guard outer 1 TIP Install the brake disc guard outer with the punched burrs 2 on the wheel hub side 2 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of rotation A of the wheel 3 Tighten Wheel nut T R Wheel nut 45 Nm 4 5 m kg 32 ft lb ...

Page 134: ...els Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear wheels Place the vehicle on a level surface 1 Rear wheel 2 2 Cotter pin 2 3 Rear wheel axle nut 2 4 Rear wheel hub 2 For installation reverse the removal proce dure ...

Page 135: ...the rear wheel hubs 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace EAS29450 INSTALLING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Install Rear axle washers 1 Rear axle nuts 2 Cotter pins 3 a Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear ...

Page 136: ...THE REAR WHEELS The following procedure applies to both of the rear wheels 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of rotation A of the wheel 2 Tighten Wheel nut T R Wheel nut 45 Nm 4 5 m kgf 32 ft lbf ...

Page 137: ...P Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pads will be forced shut 6 Brake disc brake disc bracket 1 1 7 Rear axle 1 8 Circlip 1 9 Driven sprocket sprocket bracket 1 1 10 Circlip 1 11 Brake caliper bracket 1 16 16 1 1 2 3 7 5 6 4 4 4 11 10 12 17 15 15 14 14 13 8 9 LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 33 Nm 3 3 m kg 24 ...

Page 138: ...se the removal proce dure Removing the rear axle and rear axle hub Order Job Parts to remove Q ty Remarks 16 16 1 1 2 3 7 5 6 4 4 4 11 10 12 17 15 15 14 14 13 8 9 LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 33 Nm 3 3 m kg 24 ft Ib T R 240 Nm 24 0 m kg 170 ft lb T R 34 Nm 3 4 m kg 24 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R ...

Page 139: ... hubs Rear axle ring nut Conical spring washer 7 Remove Rear axle 1 with rear wheel sprocket NOTICE ECA16180 Never directly tap the axle end with a ham mer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the left 8 Remove Circlip Rear wheel sprocket bracket EAS29500 CHECKING THE REA...

Page 140: ...EAS29530 INSTALLING THE REAR AXLE 1 Install Conical spring washer 1 Rear axle ring nut TIP Install the conical spring washer with the convex side of the washer facing outward as shown 2 Install Rear wheels Refer to REAR WHEELS on page 4 9 3 Tighten Rear axle ring nut 1 Rear axle ring nut set bolts 2 TIP Apply the brake pedal so that the rear axle does not turn when tightening the nut Use the axle ...

Page 141: ...REAR AXLE AND REAR AXLE HUB 4 16 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 2 2 1 ...

Page 142: ...wing procedure applies to both of the front brake calipers Front wheel Refer to FRONT WHEELS on page 4 5 1 Brake caliper bolt 2 2 Brake pad retaining bolt 2 3 Brake pad pad shim 2 1 4 Brake pad spring 1 For installation reverse the removal proce dure T R 28 Nm 2 8 m kg 20 ft Ib 2 3 T R 17 Nm 1 7 m kg 12 ft Ib 4 1 1 LT ...

Page 143: ...ke fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch connector 2 Disconnect 4 Front brake light switch 1 5 Brake lever 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 144: ...Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 145: ... Brake fluid Drain Front wheel Refer to FRONT WHEELS on page 4 5 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad retaining bolt 2 Loosen 5 Brake caliper bolt 2 6 Brake caliper assembly 1 For installation reverse the removal proce dure 1 2 6 4 3 5 T R 27 Nm 2 7 m kg 19 ft Ib New T R 28 Nm 2 8 m kg 20 ft Ib LT 17 Nm 1 7 m kg 12 ft Ib T R ...

Page 146: ...ke calipers 1 Brake caliper retaining bolt 2 2 Brake pad pad shim 2 1 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 2 6 Brake caliper dust seal 2 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure New T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib 8 7 6 4 1 2 3 New LT 5 BF S S ...

Page 147: ...tes and get im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEELS on page 4 5 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Hold the dial gauge at a right angle against the brake ...

Page 148: ... 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 4 Install Brake pad retaining bolt Brake caliper 5 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to C...

Page 149: ...ke caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA1S3L005 Whenever a brake caliper is disassembled replace the brake caliper piston seals and dust seals EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers...

Page 150: ...e recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not ent...

Page 151: ...ce 3 Check Brake master cylinder reservoir 1 Cracks damage Replace Brake master cylinder reservoir diaphragm 2 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA1S3L007 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake ...

Page 152: ...d that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir 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 alw...

Page 153: ...s Order Job Parts to remove Q ty Remarks 1 Brake caliper bolt 2 2 Brake pad retaining bolt 2 3 Brake pad insulator pad shim 2 1 1 4 Brake pad spring 1 For installation reverse the removal proce dure LT 3 4 2 T R 17 Nm 1 7 m kg 12 ft Ib 1 T R 34 Nm 3 4 m kg 24 ft Ib ...

Page 154: ...Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Brake master cylinder 1 11 Rear brake light switch 1 12 Right footrest 1 13 Brake pedal spring 1 1 For installation reverse the removal proce dure LS T R 4 Nm 0 4 m kg 2 9 ft Ib New New T R 20 Nm 2 0 m kg 14 ft Ib 2 3 4 5 6 T R 78 Nm 7 8 m kg 56 f...

Page 155: ...KE 4 30 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder 1 For assembly reverse the disassembly pro cedure ...

Page 156: ...ks Brake fluid Drain 1 Parking brake cable 1 Disconnect 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper bolt 2 6 Brake caliper assembly 1 For installation reverse the removal proce dure 5 1 5 6 3 2 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib New ...

Page 157: ... brake arm 1 4 Parking brake shaft 1 5 Rubber boot 1 6 Parking brake bracket mounting bolt 2 7 Parking brake case bracket 1 8 Parking brake case 1 9 Gasket 1 10 Brake pad retaining bolt 2 11 Brake pad insulator pad shim 2 1 1 12 Brake pad spring 1 13 Caliper bracket 1 14 Brake caliper piston 1 15 Dust seal 1 16 Caliper piston seal 1 ...

Page 158: ...REAR BRAKE 4 33 17 Bleed screw 1 For assembly reverse the disassembly pro cedure Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks ...

Page 159: ...k Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 5 Adjust Brake disc de...

Page 160: ...a new brake pad spring TIP Align the projection c on the piston side of the brake pad with the lower recess in the brake cal iper piston 4 Install Brake pad retaining bolts Brake caliper assembly 5 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake pedal operation Soft or spongy...

Page 161: ...y Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA1S3L009 Whenever a brake caliper is disassembled replace the brake caliper piston seal and dust seal EAS22660 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA1S3L013 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents o...

Page 162: ... the parking brake arm turn the parking brake shaft clockwise and align the punch mark a on the parking brake arm with the punch mark b on the parking brake shaft EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Brake caliper assembly Brake caliper bolts 1 Brake hose 2 Copper washers 3 Union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer ...

Page 163: ...e proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 6 Adjust Parking brake cable end length a a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction b or c until the specified brake cable end length a is obtai...

Page 164: ...al brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Whenever a master cylinder is disassem bled replace the brake master cylinder kit EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hoses 1 Union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle op...

Page 165: ...he 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 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 4 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVE...

Page 166: ...e lever assembly holder 1 1 6 Spacer 1 7 Clutch switch 1 8 Parking brake lever 1 9 Clutch lever bracket 1 1 10 Handlebar switch 1 11 Handlebar grip 2 12 Handlebar holder 2 13 Handlebar 1 For installation reverse the removal proce dure 11 6 13 5 2 4 12 12 2 11 10 7 8 9 9 1 3 4 5 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3...

Page 167: ...attempt to straighten a bent handle bar as this may dangerously weaken it EAS22911 INSTALLING THE HANDLEBAR 1 Place the vehicle on a level surface 2 Install Handlebar Upper handlebar holders NOTICE ECA1S3L014 First tighten the bolts 1 on the front side of the handlebar holders and then tighten the bolts 2 on the rear side Turn the handlebar all the way to the left and right If there is any contact...

Page 168: ...ouch the handlebar grip until the rub ber adhesive has fully dried 4 Install Left handlebar switch 1 Clutch lever Clutch lever bracket 2 TIP Install the clutch lever bracket as shown 5 Install Brake master cylinder 1 TIP Install the brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 6 Install Spacer Throttle lever assembly TIP Fit the indentati...

Page 169: ...t of lithium soap based grease 9 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 10 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LE VER FREE PLAY on page 3 7 Clutch lever free play lever end 5 0 10 0 mm 0 20 0 39 in Throttle lever free play 2 0 4 0 mm 0 08 0 16 in a b ...

Page 170: ...o remove Q ty Remarks Front fender fuel tank Refer to GENERAL CHASSIS on page 4 1 1 Pitman arm 1 2 Lock washer 1 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Oil seal 1 8 Oil seal 1 9 Bearing retainer 1 10 Bearing 1 For installation reverse the removal proce dure ...

Page 171: ...LOCK WASHER 1 Install Lock washer Steering stem bushing bolts 2 Bend the lock washer tabs along a flat side of the bolts EAS29590 INSTALLING THE PITMAN ARM 1 Install Pitman arm Washer Pitman arm nut Cotter pin TIP Make sure that the threads of the steering stem washers nuts and the installation surfaces of the pitman arm are free of grease and oil Damper rod holder 30 mm 90890 01327 YM 01327 T R B...

Page 172: ...following procedure applies to both of the tie rods and steering knuckles Front wheel brake disc Refer to FRONT WHEELS on page 4 5 Front brake caliper Refer to FRONT BRAKES on page 4 17 1 Brake disc guard inner 1 2 Tie rod 2 3 Pitman arm 1 4 Front guard 1 5 Lower front arm 1 6 Upper front arm 1 7 Steering knuckle 1 For installation reverse the removal proce dure ...

Page 173: ...free play and movement Free play Replace the tie rod end Rough movement Replace the tie rod end 2 Check Tie rod Bends damage Replace EAS29690 CHECKING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles 1 Check Steering knuckle Damage pitting Replace EAS29700 INSTALLING THE TIE RODS The following procedure applies to both of the tie rods 1 Install Tie rod TIP Ins...

Page 174: ...nt wheel brake disc Refer to FRONT WHEELS on page 4 5 Front brake caliper Refer to FRONT BRAKES on page 4 17 Steering knuckle Refer to TIE RODS AND STEERING KNUCKLES on page 4 47 1 Nut washer bolt 1 1 1 2 Nut bolt 2 2 3 Lower front arm 1 4 Nut bolt 1 1 5 Upper front arm 1 6 Nut bolt 1 1 7 Front shock absorber 1 8 Dust cover 6 9 Spacer 1 10 Spacer 2 6 4 5 8 11 2 2 11 9 6 4 2 11 11 11 8 8 10 1 12 13...

Page 175: ...nt 1 For installation reverse the removal proce dure Removing the front arms and front shock absorber assemblies Order Job Parts to remove Q ty Remarks 6 4 5 8 11 2 2 11 9 6 4 2 11 11 11 8 8 10 1 12 13 14 1 3 11 10 8 7 38 Nm 3 8 m kg 27 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R ...

Page 176: ...rformance EAS1S3L018 DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY 1 Gas pressure must be released before dis posing of a front shock absorber assembly To release the gas pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS29720 REM...

Page 177: ...ure applies to each of the front arm ball joints 1 Check Ball joint front upper arm Damage pitting Replace the front upper arm Free play Replace the front upper arm Rough movement Replace the front upper arm 2 Check Ball joint front lower arm Damage pitting Replace the ball joint Free play Replace the ball joint Rough movement Replace the ball joint a Clean the surface of the front lower arm b Rem...

Page 178: ...joint remover installer h Install a new circlip TIP Always use a new ball joint set EAS29790 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front upper arms front lower arms and front shock absorber assemblies 1 Install Front upper arm Front lower arm Front shock absorber assembly a Install the front upper arm 1 and front lower arm 2 TI...

Page 179: ...cotter pins e Tighten the front upper and lower arm nuts to specification T R Upper steering knuckle nut 25 Nm 2 5 m kg 18 ft lb Lower steering knuckle nut 25 Nm 2 5 m kg 18 ft lb T R Front upper arm nut 38 Nm 3 8 m kg 27 ft lb Front lower arm nut 55 Nm 5 5 m kg 40 ft lb ...

Page 180: ...1 4 Self locking nut bolt 1 1 5 Rear shock absorber assembly 1 6 Spacer oil seal bearing 1 2 1 7 Spacer oil seal bearing 1 2 1 8 Self locking nut bolt 1 1 9 Relay arm 1 10 Spacer oil seal bushing 1 2 2 11 Connecting arm 1 12 Dust cover 4 13 Spacer 1 14 Spacer 1 LS LS LS LS New LS LS LS New LS LS 2 2 2 1 1 1 6 3 6 LS 7 5 3 12 12 12 8 9 7 4 4 10 10 8 12 11 13 15 15 15 14 15 New New New New T R 55 Nm...

Page 181: ... rear shock absorber assembly Order Job Parts to remove Q ty Remarks LS LS LS LS New LS LS LS New LS LS 2 2 2 1 1 1 6 3 6 LS 7 5 3 12 12 12 8 9 7 4 4 10 10 8 12 11 13 15 15 15 14 15 New New New New T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 182: ...orber assembly To release the gas pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Place the vehicle on a level surface TIP Place the vehicle on a suitable stand so that the rear...

Page 183: ...rm TIP Apply lithium soap based grease on the bush ings when installing 2 Install Bushing 1 Oil seal 2 to relay arm TIP Apply lithium soap based grease on the bush ings when installing 3 Install Connecting arm Relay arm Rear shock absorber TIP When installing the rear shock absorber lift up the swingarm Installed depth of bushing a 1 0 mm 0 04 in Installed depth of bushing a 6 5 mm 0 26 in New ...

Page 184: ...ORBER AS SEMBLY on page 4 55 1 Rear axle pinch bolt 4 2 Dust seal 1 3 Swingarm skid plate 1 4 Drive chain guide 1 1 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Dust cover washer 2 2 9 Spacer 2 10 Oil seal 2 11 Bushing 2 7 3 2 4 1 6 4 8 9 12 11 11 10 10 12 9 8 5 100 Nm 10 0 m kg 72 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 55 Nm 5 5 m kg 40...

Page 185: ...oval proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 7 3 2 4 1 6 4 8 9 12 11 11 10 10 12 9 8 5 100 Nm 10 0 m kg 72 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R ...

Page 186: ...frame pivot 3 Remove Pivot shaft nut Washer Pivot shaft Swingarm EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Clean Pivot shaft Spacers Bearings Bushings 4 Check Dust covers Spacers Oil seals Damage wear Replace Bearings Bushings...

Page 187: ...assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 4 Install Rear wheels Refer to and REAR WHEELS on page 4 9 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 Drive chain slack 25 0 35 0 mm 0 98 1 38 in 1 2 2 1 b a ...

Page 188: ...garm Refer to SWINGARM on page 4 59 1 Drive sprocket cover 1 2 Drive chain guide 2 1 3 Drive sprocket nut 1 4 Lock washer 1 5 Drive sprocket 1 6 Drive chain 1 For installation reverse the removal proce dure 1 2 5 3 4 6 85 Nm 8 5 m kg 61 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R New ...

Page 189: ...n 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 motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain sol vents e g benzine or a coarse brush to clean the drive chain High pressu...

Page 190: ...Drive chain Drive sprocket 1 Lock washer 2 Drive sprocket nut 3 Drive chain guide TIP While applying the rear brake tighten the drive sprocket nut 3 Bend the lock washer tab along a flat side of the nut Recommended lubricant Engine oil or chain lubricant suitable for O ring chains b Correct 1 Drive chain roller 2 Drive chain sprocket Recommended lubricant Engine oil or chain lubricant suitable for...

Page 191: ...ALLING THE CAMSHAFT AND ROCKER ARMS 5 16 VALVES AND VALVE SPRINGS 5 19 REMOVING THE VALVES 5 20 CHECKING THE VALVES AND VALVE GUIDES 5 20 CHECKING THE VALVE SEATS 5 22 CHECKING THE VALVE SPRINGS 5 23 INSTALLING THE VALVES 5 24 CYLINDER AND PISTON 5 26 REMOVING THE PISTON 5 27 CHECKING THE CYLINDER AND PISTON 5 27 CHECKING THE PISTON RINGS 5 28 CHECKING THE PISTON PIN 5 29 INSTALLING THE PISTON AND...

Page 192: ...ING THE OIL PUMP 5 52 SHIFT SHAFT 5 53 CHECKING THE SHIFT SHAFT 5 54 CHECKING THE STOPPER LEVER 5 54 CHECKING THE SHIFT GUIDE 5 54 CHECKING THE SHIFT DRUM SEGMENT 5 54 INSTALLING THE SHIFT LEVER 5 54 INSTALLING THE SHIFT SHAFT 5 55 CRANKCASE 5 56 SEPARATING THE CRANKCASE 5 59 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 59 CHECKING THE OIL STRAINER 5 59 CHECKING THE BEARINGS AND OIL SEALS 5 ...

Page 193: ......

Page 194: ...uffler 1 2 Muffler protector 1 3 Gasket 1 4 Exhaust pipe 1 1 5 Gasket 1 6 Exhaust pipe 2 1 7 Exhaust pipe protector 1 8 Gasket 2 For installation reverse the removal proce dure LT T R 38 Nm 3 8 m kg 27 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New New New LT LT LT 1 2 3 4 6 7 5 8 8 ...

Page 195: ...d 3 TIP Tighten the exhaust pipe nuts in the order 1 2 3 2 Install Gasket 1 to muffler TIP Install the gasket with the chamfer a located on an inner rim of the gasket and the chamfer b located on an outer rim of the gasket as shown Installed depth of gasket c 1 0 1 5 mm 0 04 0 06 in 3 3 1 2 New a c 1 b New ...

Page 196: ...nlet hose 1 3 Oil tank outlet hose 1 4 Oil tank breather hose 1 5 Oil tank 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 19 Nm 1 9 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 2 1 3 4 5 New New LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib ...

Page 197: ... Refer to THERMOSTAT on page 6 3 Radiator outlet hose Refer to WATER PUMP on page 6 5 Throttle body Refer to THROTTLE BODY on page 7 4 Drive sprocket Refer to CHAIN DRIVE on page 4 63 1 Spark plug cap 1 2 Starter motor lead 1 3 Coolant temperature sensor coupler 1 Disconnect 4 Plastic band 1 5 Wire sub lead coupler 1 6 Speed sensor coupler 1 7 AC magneto coupler 1 Disconnect 8 Crankshaft position ...

Page 198: ...ire harness 1 12 Ground lead 1 13 Clutch cable 1 14 Parking brake cable 1 15 Reverse control cable 1 For installation reverse the removal proce dure Disconnecting the leads cables and hoses Order Job Parts to remove Q ty Remarks ...

Page 199: ...ne mounting bolt lower nut 1 1 8 Pivot shaft pivot shaft nut 1 1 Refer to REMOVING THE SWINGARM on page 4 61 9 Engine assembly 1 TIP Remove the engine assembly from the right side of the vehicle For installation reverse the removal proce dure T R 66 Nm 6 6 m kg 48 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 41 Nm 4 1 m kg 30 ft Ib T R 41 Nm 4 1 m kg 30 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 6 5 4 6 4 5 7 8 2...

Page 200: ...ut TIP Do not fully tighten the bolts and nuts 3 Tighten Engine upper bracket bolt 1 Engine upper bracket bolt 2 Engine mounting bolt upper nut 3 Pivot shaft nut 4 Engine mounting bolt lower nut 5 Engine mounting bolt middle nut 6 Engine lower bracket bolts 7 TIP Tighten the bolts and nuts in the proper tighten ing sequence as shown T R Engine upper bracket bolt 1 33 Nm 3 3 m kg 24 ft lb Engine up...

Page 201: ...in tensioner gasket 1 1 8 Camshaft sprocket 1 9 Decompressor assembly 1 10 Cylinder head 1 11 Cylinder head gasket 1 12 Dowel pin 2 For installation reverse the removal proce dure LS M LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 38 Nm 3...

Page 202: ...iming chain tensioner along with the gasket Camshaft sprocket Timing chain TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove Cylinder head TIP Loosen the nuts in the proper sequence as shown Loosen each nut 1 2 of a turn at a time After all of the nuts are fully loosened remove them EAS24160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carb...

Page 203: ...Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS23940 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O rings 1 Check Tappet covers 1 Camshaft sprocket cover 2 O ring Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing...

Page 204: ... Camshaft sprocket Timing chain a Turn the crankshaft counterclockwise b Align the I mark a on the AC magneto rotor with the stationary pointer b on the AC mag neto cover c Align the I mark c on the camshaft sprock et with the stationary pointer d on the cylin der head d Install the timing chain 1 onto the camshaft sprocket 2 and then install the camshaft sprocket onto the camshaft TIP When instal...

Page 205: ...tensioner and gasket 6 onto the cylinder TIP Install the gasket with its beaded side facing the timing chain tensioner end d Install the spring and timing chain tensioner cap bolt 5 Turn Crankshaft several turns counterclockwise 6 Check I mark a Align the I mark on the AC magneto rotor with the stationary pointer b on the AC mag neto cover I mark c Align the I mark on the camshaft sprocket with th...

Page 206: ... to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 ...

Page 207: ... 1 2 Rocker arm shaft 2 3 Rocker arm 2 4 Locknut valve adjuster 4 4 5 Camshaft 1 NOTICE ECA1S3L017 Do not disassemble the camshaft assem bly 6 Decompressor lever 1 7 Decompressor lever pin 1 8 Bearing 1 For installation reverse the removal proce dure E E T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E LT 1 5 7 6 2 E 8 3 2 3 4 4 4 4 E M ...

Page 208: ...tches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 1 1 2 Camshaft lobe dimension limit Intake A 43 300 43 400 mm 1 7047 1 7087 in Limit 43 200 mm 1 7008 in Intake B 37 026 37 126 mm 1 4577 ...

Page 209: ...e discoloration excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance Out of specification Replace the defective part s TIP Calculate the clearance by subtracting the rock er arm shaft ou...

Page 210: ... holes b 5 Lubricate Rocker arms Rocker arm shafts 6 Install Exhaust rocker arm 1 Exhaust rocker arm shaft 2 Intake rocker arm Intake rocker arm shaft TIP Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head 7 Install Camshaft retainer Camshaft retainer bolts Installed depth b 0 mm 0 in Recommended lubricant Ca...

Page 211: ...CAMSHAFT 5 18 T R Camshaft retainer bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 212: ... Refer to CYLINDER HEAD on page 5 8 Rocker arms rocker arm shafts camshaft Refer to CAMSHAFT on page 5 14 1 Valve cotter 8 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 For installation reverse the removal proce dure New M M New New M M M 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 ...

Page 213: ...tters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Valve spring retainer Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The follo...

Page 214: ...er valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 1...

Page 215: ...itting 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 b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one anoth...

Page 216: ...h be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear i...

Page 217: ... 1 Valve stem seal 2 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 b Installed length Installed compression spring force intake 169 00 199 00 N 17 23 20 29 kgf 37 99 44 73 lbf Installed compression spring force exhaust 169 00 199 00 N 17 23 20 29 kgf 37 99 44 73 lbf Installed length intake 35 00 ...

Page 218: ...e spring with the valve spring compressor 1 and the valve spring compressor attachment 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 b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compres...

Page 219: ...ater jacket joint 1 3 O ring 1 4 Cylinder 1 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 8 Piston pin 1 9 Piston 1 10 Top ring 1 11 2nd ring 1 12 Oil ring 1 For installation reverse the removal proce dure T R 1st 15Nm 1 5 m kg 11 ft lb 2nd 50Nm 5 0m kg 5 1 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib New 7 6 6 5 9 New New 7 New 3 10 1 2 8 11 12 4 T R 10 Nm 1 0 m kg 7 2 ft Ib LS E E E E T R 7 Nm 0 7...

Page 220: ...2 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 piston crown EAS24400 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the ...

Page 221: ...the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown Bore 102 000 102 010 mm 4 0157 4 0161 in Wear limit 102 080 mm 4 0189 in Taper limit 0 05 mm 0 002 Out of round limit 0 05 mm 0 002 in a 10 mm 0 39 in from the bottom edge of the piston D...

Page 222: ...and piston as a set EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up Top ring End gap installed 0 20 0 35 mm 0 008 0 014 in Limit 0 60 mm 0 024 in 2nd ring End gap installed 0 75 0 90 mm 0 03 0 04 in Limit 1 25 mm 0 0...

Page 223: ...g chain guide exhaust side TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 7 Install Cylinder bolts 1 TIP Lubricate the cylinder bolt 1 threads and mat ing surface with engine oil 8 Tighten Cylinder bolts 1 Cylinder bolts timing chain side 2 Recommended lubricant ...

Page 224: ...t cover Refer to CHAIN DRIVE on page 4 63 1 AC magneto coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 AC magneto cover 1 4 AC magneto cover gasket 1 5 Dowel pin 2 6 Lead holder 1 7 Crankshaft position sensor 1 8 Stator coil 1 9 Torque limiter 1 10 Starter idle gear 1 LT LT E LS New LT E E E New LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m ...

Page 225: ...allation reverse the removal proce dure Removing the AC magneto and starter clutch Order Job Parts to remove Q ty Remarks LT LT E LS New LT E E E New LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 8 3 4 14 3 15 5 16 11 9 14 10 13 12 7 6 1 2 T R 60 Nm 6 0 m kg 43 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 226: ... of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Use the flywheel puller 2 Install the flywheel puller bolts to the threaded holes of the starter clutch Make sure the flywheel puller is centered over the AC magneto rotor EAS1S3L027 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1 Check Stator coil 1 Crankshaft positi...

Page 227: ...h and the start er wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS1S3L028 CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace TIP Do not disassemble the torque limiter EAS1S3L029 INSTALLING THE AC MAGNETO 1 ...

Page 228: ...aft 4 Tighten AC magneto rotor nut 1 TIP While holding the AC magneto rotor 2 with the sheave holder 3 tighten the AC magneto rotor nut Do not allow the sheave holder to touch the projection on the AC magneto rotor 5 Install Gasket AC magneto cover AC magneto cover bolts TIP Tighten the AC magneto cover bolts in stages using a crisscross pattern Yamaha bond No 1215 90890 85505 Three Bond No 1215 T...

Page 229: ... Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Parking brake cable 1 3 Starter motor 1 For installation reverse the removal proce dure T R 5 Nm 0 5 m kg 3 6 ft Ib 3 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 230: ...emove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Square ring 1 4 Lock washer 1 5 Shim 1 6 Armature assembly 1 7 Starter motor yoke 1 8 Brush holder assembly 1 9 Square ring 1 10 Shim 1 11 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 231: ...r and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket 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 Commutator diameter 28 0 mm 1 10 in Li...

Page 232: ...R MOTOR 1 Install Brush seat 1 TIP Align the tab a on the brush seat with the slot b in the starter motor yoke 2 Install Starter motor yoke Starter motor front cover Starter motor rear cover TIP Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers Brush spring force 7 65 10 01 N 780 1021 gf 27 54 36 03 oz b b a ...

Page 233: ...er to REAR BRAKE on page 4 28 Oil delivery pipe Refer to CYLINDER HEAD on page 5 8 1 Oil filter cover O ring 1 1 2 Oil filter 1 3 O ring 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil seal retainer 1 For installation reverse the removal proce dure LS LS LS LS 1 6 5 7 6 4 2 New 3 14 New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12...

Page 234: ...ft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal proce dure E 5 8 7 6 4 3 2 1 New New New LS ...

Page 235: ... damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss 1 13 Thrust washer 1 14 Clutch housing 1 15 Breather plate 1 16 Lock washer 1 17 Balancer driven gear 1 1 25 24 22 LS New 19 New New 16 14 17 New T R 8 Nm 0 8 m kg 5 8 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R 95 Nm 9 5 m kg 68 ft Ib 1 5 6 6 2 4 3 18 23 ...

Page 236: ...ight key 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 25 24 22 LS New 19 New New 16 14 17 New T R 8 Nm 0 8 m kg 5 8 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R 95 Nm 9 5 m kg 68 ft Ib 1 5 6 6 2 4 3 18 23 26 E E 21 20 7 8 6 9 10 11 15 12 13 E E E E M ...

Page 237: ...Y DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Straighten the lock washer tabs 2 Remove Balancer driven gear 1 nut 1 Primary drive gear nut 2 Balancer driven gear 2 nut 3 TIP Place an aluminum plate 4 between the teeth of the balancer driven gear 1 5 and balancer drive gear 6 then loosen the nut 1 Place an aluminum plate 4 between the teeth of the balancer driven gear 2 8 and balancer drive gear 6 then l...

Page 238: ...ee length a Out of specification Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP...

Page 239: ...ancer drive gear and balancer driven gear as a set Replace the water pump drive gear and water pump driven gear as a set Excessive noise during operation Replace the balancer drive gear and balancer driven gear as a set Replace the water pump drive gear and water pump driven gear as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth a Pull rod teet...

Page 240: ...eth of the balancer drive gear 6 and balancer driven gear 1 7 then tighten the nut 3 3 Bend the lock washer tabs along a flat side of the nut EAS25240 INSTALLING THE CLUTCH 1 Install Clutch housing 1 TIP Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Make sure that the oil pump drive gear teeth and oil pump driven gear teeth mesh correctly 2 Install Clutch...

Page 241: ...attern 6 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP Install the pull lever with the UP mark facing up Align the mark a on the pull lever with the sta tionary pointer b on the clutch cover Install the pull lever spring 1 as shown 7 Install Clutch cable 1 8 Check Clutch cable length a Out of specification Adjust TIP Push the pull lever in direction b and check the cable length a Ben...

Page 242: ...49 9 Adjust Clutch cable length TIP Move the pull lever a notch until the cable length is within specification 10 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 b a 1 c ...

Page 243: ...rder Job Parts to remove Q ty Remarks Clutch housing Refer to CLUTCH on page 5 40 1 Oil baffle plate 1 1 2 Circlip 1 3 Oil pump driven gear 1 4 Oil baffle plate 2 1 5 Oil pump 1 6 Oil pump gasket 1 7 O ring 2 For installation reverse the removal proce dure ...

Page 244: ...ng 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 10 Oil pump outer rotor 2 1 11 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure ...

Page 245: ... 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump outer rotor 2 1 Oil pump inner rotor 2 2 to the oil pump housing 2 Oil pump housing TIP Align the match mark a on the inner rotor 2 with the match mark b on the outer rotor 2 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 52 Inner rotor to outer rotor tip clearance 0 12 mm 0 0...

Page 246: ...utch housing Refer to CLUTCH on page 5 40 1 Shift pedal 1 2 Shift shaft 1 3 Shift shaft spring 1 4 Stopper lever washer 1 1 5 Stopper lever spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Pawl holder 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Shift drum segment 1 For installation reverse the removal proce dure ...

Page 247: ...AS1S3L033 CHECKING THE SHIFT GUIDE 1 Check Shift guide 1 Pawl holder 2 Pawls 3 Pawl pins 4 Springs 5 Wear cracks damage Replace EAS1S3L034 CHECKING THE SHIFT DRUM SEGMENT 1 Check Shift drum segment Damage wear Replace EAS1S3L035 INSTALLING THE SHIFT LEVER 1 Install Shift drum segment 1 Shift drum segment bolt TIP Align the notch a on the shift drum segment with the pin b on the shift drum 2 Instal...

Page 248: ...shaft 3 Roller 4 Shift shaft spring TIP Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 5 Install the end of the shift shaft spring onto the shift shaft spring stopper 6 Install the end of the shift shaft lever onto the roller 4 2 Install Shift pedal Refer to ADJUSTING THE SHIFT PEDAL on page 3 25 T R Shift guide bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 4 3 3 2...

Page 249: ...Refer to AC MAGNETO AND STARTER CLUTCH on page 5 31 Balancer driven gears Refer to CLUTCH on page 5 40 Oil pump Refer to OIL PUMP on page 5 50 Shift drum segment Refer to SHIFT SHAFT on page 5 53 Starter motor Refer to ELECTRIC STARTER on page 5 36 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral switch 1 4 Reverse switch 1 5 Oil pipe joint 1 6 Reverse shift lever 1 7 Reverse shift le...

Page 250: ...Circlip 1 9 Right crankcase 1 10 Left crankcase 1 11 Dowel pin 2 12 Dowel pin O ring 1 1 13 Oil strainer 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 251: ...ansmission Refer to TRANSMISSION on page 5 65 1 Oil seal retainer 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 4 5 Bearing 10 For installation reverse the removal proce dure LS LS LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E 5 5 3 3 5 5 LT 5 4 4 1 5 5 5 2 5 5 E E E E New New T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 252: ...wly and carefully and make sure the crankcase halves sepa rate evenly EAS1S3L023 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprockets as a set 2 Check Timing chain guide intake side Damage wear Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with ...

Page 253: ...nt the bearing retainer screws 2 from becoming loose flatten the edge a of each screw into the depression b using a punch etc Be careful not to damage the hole for the screwdriver in the screw heads 2 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 3 Apply Sealant 1 onto the crankcase mating surfaces TIP Do not allow any sealant to come into contact with the oil gall...

Page 254: ...smission is functioning properly by manually rotating the shift drum in both di rections 6 Install Crankcase bolts 7 Tighten Crankcase bolts TIP Tighten the bolts in stages using a crisscross pattern 8 Apply Engine oil to the crankshaft pin bearing and oil delivery hole 9 Check Crankshaft and transmission operation Rough operation Repair A Left crankcase B Right crankcase T R Crankcase bolt 10 Nm ...

Page 255: ...0 CRANKSHAFT Removing the crankshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Balancer 1 1 2 Balancer 2 1 3 Crankshaft 1 For installation reverse the removal proce dure 2 1 3 ...

Page 256: ...k shaft EAS1S3L040 INSTALLING THE CRANKSHAFT 1 Install Crankshaft 1 TIP Install the crankshaft with the crankshaft installer pot 2 crankshaft installer bolt 3 adapter M16 4 and spacer crankshaft installer 5 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B Width A 74 95 75 00 mm 2 951 2 953 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 650 mm 0 0138 0 025...

Page 257: ...ft against scratches and to make installation easier TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing 1 5 4 3 2 ...

Page 258: ...ANKCASE on page 5 56 1 Spacer 1 2 Circlip 1 3 Washer 1 4 Reverse wheel gear 2 1 5 Spacer 1 6 Counter axle assembly 1 7 Shift drum 1 8 Shift fork R 1 9 Shift fork C 1 10 Shift fork L 1 11 Drive axle assembly 1 12 Main axle assembly 1 13 Reverse shift shaft 1 For installation reverse the removal proce dure M 12 13 New New New New New New New 9 7 10 8 2 3 4 5 11 6 1 New LS ...

Page 259: ...d pinion gear 1 3 Toothed lock washer 1 4 Toothed washer retainer 1 5 4th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 8 Circlip 2 9 3rd pinion gear 1 10 5th pinion gear 1 11 Main axle 1st pinion gear 1 For installation reverse the removal proce dure 11 10 7 8 9 8 1 2 3 4 5 6 7 New New New M M M ...

Page 260: ...cer 1 5 Dog clutch 1 6 Circlip 1 7 Toothed washer 1 8 1st wheel gear 1 9 Toothed spacer 1 10 5th wheel gear 1 11 Toothed lock washer 1 12 Toothed washer retainer 1 13 3rd wheel gear 1 14 Toothed spacer 1 15 Toothed washer 1 16 Circlip 1 17 4th wheel gear 1 M M M 22 21 11 2 3 4 5 6 7 8 9 10 1 12 13 14 15 16 17 19 20 18 New New New New M M M ...

Page 261: ...1 20 2nd wheel gear 1 21 Spacer 1 22 Drive axle 1 For installation reverse the removal proce dure Disassembling the drive axle Order Job Parts to remove Q ty Remarks M M M 22 21 11 2 3 4 5 6 7 8 9 10 1 12 13 14 15 16 17 19 20 18 New New New New M M M ...

Page 262: ... Disassembling the counter axle Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Washer 2 3 Spacer 1 4 Reverse wheel gear 1 1 5 Counter axle 1 For installation reverse the removal proce dure 5 4 3 2 1 2 1 New New M ...

Page 263: ...ork guide bar 3 Check Shift fork movement Rough movement Replace the shift forks EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Check Transmission gears Blue discoloration pitt...

Page 264: ...ll Drive axle assembly 1 Main axle assembly 2 Shift fork L 3 to drive axle Shift fork C 4 to main axle Shift fork R 5 to drive axle Shift drum 6 TIP 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 Be sure that the shift fork cam follower is properly seated in the shift drum groove 2 Install Counter axle assembly TIP Enga...

Page 265: ...TRANSMISSION 5 72 ...

Page 266: ...TRANSMISSION 5 73 ...

Page 267: ...CHECKING THE RADIATOR 6 2 INSTALLING THE RADIATOR 6 2 THERMOSTAT 6 3 CHECKING THE THERMOSTAT 6 4 INSTALLING THE THERMOSTAT 6 4 WATER PUMP 6 5 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 ...

Page 268: ...r hose 1 3 Radiator fan motor breather hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Radiator inlet hose 1 Disconnect 6 Fast idle plunger outlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Coolant reservoir breather hose 1 10 Coolant reservoir 1 11 Coolant reservoir cap 1 For installation reverse the removal proce dure 1 4 8 2 2 10 11 9 5 6 3 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm ...

Page 269: ...and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 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 18 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure ...

Page 270: ...nder Refer to GENERAL CHASSIS on page 4 1 Coolant Drain 1 Radiator inlet hose 1 2 Thermostat cover 1 3 O ring 1 4 Thermostat 1 5 Coolant temperature sensor 1 6 Copper washer 1 For installation reverse the removal proce dure LS 5 6 2 3 4 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New ...

Page 271: ...he thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Thermostat housing cylinder head Cracks damage Replace EAS1S3L009 INSTALLING THE THERMOSTAT 1 Install Thermostat 1 O ring 2 Thermostat cover 3 TIP Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mend...

Page 272: ...ely low or the coolant contains engine oil Coolant Drain 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump 1 4 O ring 1 5 Water pump breather hose 1 6 Water jacket inlet housing 1 7 O ring 1 For installation reverse the removal proce dure LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New 1 2 5 7 6 New 4 3 LS ...

Page 273: ...ing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller shaft gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft assembly 1 8 Water pump seal 1 9 Oil seal 1 10 Bearing 1 11 Water pump housing 1 For assembly reverse the disassembly pro cedure E 7 5 10 6 4 8 11 New 2 1 New New 3 New 9 New LS T R 11 Nm 1 1 m kg 8 0 ft Ib ...

Page 274: ...g wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket 3 that match es its outside diameter 2 Install Water pump seal 1 into the water pump housing 2 NOTICE ECA14080 Never lubricate the water pump seal surface with oil or grease TIP I...

Page 275: ...ATER PUMP 6 8 3 Measure Impeller shaft tilt 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller 4 A 1 2 3 New ...

Page 276: ...WATER PUMP 6 9 ...

Page 277: ...HECKING THE FUEL PUMP BODY 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL HOSE 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING THE PRESSURE REGULATOR OPERATION 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 INSTALLING THE THROTTLE BODY 7 8 ...

Page 278: ...l hose connector holder 1 3 Fuel hose 1 4 Fuel tank 1 TIP When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar cover and then insert the end of the hose into the steering stem 5 Drain hose 1 6 Fuel tank shield 1 7 Fuel pump 1 For installation reverse the removal proce dure 4 2 1 7 3 6 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m...

Page 279: ...he hose Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or like EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock D...

Page 280: ... the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector cover 1 securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose 1 3 5 2 4 6 a a 1 1 ...

Page 281: ...take air pressure sensor coupler 1 Disconnect 4 Throttle position sensor coupler 1 Disconnect 5 Throttle cable housing cover 1 6 Throttle cable 1 7 Hose air filter joint to throttle body left side 1 Disconnect 8 Fast idle plunger inlet hose 1 9 Fast idle plunger outlet hose 1 Disconnect 10 Intake air pressure sensor hose 1 11 Intake air pressure sensor 1 12 Intake manifold clamp screw 1 Loosen 4 N...

Page 282: ...mp screw 1 Loosen 14 Throttle body assembly 1 For installation reverse the removal proce dure Removing the throttle body Order Job Parts to remove Q ty Remarks 4 Nm 0 4 m kg 2 9 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 12 13 1 2 3 4 5 6 7 8 9 10 11 14 ...

Page 283: ...Order Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 4 Throttle body 1 NOTICE ECA1S3L008 The throttle body should not be disas sembled For assembly reverse the disassembly pro cedure 3 2 4 1 New ...

Page 284: ...he slot part a of the fuel hose connec tor cover 2 then slide it in the direction of the arrow and remove the fuel hose Before removing the hose place a few rags in the area under where it will be removed d Connect the pressure gauge 3 and adapter 4 to the fuel pump and fuel hose e Start the engine f Measure the fuel pressure Out of specification Replace the fuel pump EAS27030 ADJUSTING THE THROTT...

Page 285: ...n the projection a on the throttle body with the slot b in the throttle body joint 2 Install Throttle cable 3 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LE VER FREE PLAY on page 3 7 4 Adjust Engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 6 5 Check Throttle position sensor Refer to ADJUSTING THE THROTTLE PO SITION SENSOR on page 7 7 Digital circuit tes...

Page 286: ...THROTTLE BODY 7 9 ...

Page 287: ... 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 SELF DIAGNOSTIC FUNCTION TABLE 8 31 TROUBLESHOOTING METHOD 8 33 DIAGNOSTIC MODE 8 33 TROUBLESHOOTING DETAILS 8 38 FUEL PUMP...

Page 288: ...ING THE CRANKSHAFT POSITION SENSOR 8 68 CHECKING THE LEAN ANGLE SENSOR 8 68 CHECKING THE STARTER MOTOR OPERATION 8 69 CHECKING THE STATOR COIL 8 69 CHECKING THE RECTIFIER REGULATOR 8 70 CHECKING THE FUEL SENDER 8 70 CHECKING THE SPEED SENSOR 8 71 CHECKING THE RADIATOR FAN MOTOR 8 71 CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 8 71 CHECKING THE COOLANT TEMPERATURE SENSOR 8 72 CHECKING THE THROT...

Page 289: ......

Page 290: ...B Br L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R B Y R Br...

Page 291: ...IGNITION SYSTEM 8 2 1 Crankshaft position sensor 4 Main switch 6 Battery 7 Main fuse 21 ECU engine control unit 22 Ignition coil 23 Spark plug 30 Lean angle sensor 36 Engine stop switch 45 Ignition fuse ...

Page 292: ...tery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 8 Re gap clean or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 67 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 66 Replace the spark plug cap 6 Check the ignition coil Refer to...

Page 293: ... to CHECKING THE SWITCHES on page 8 57 The engine stop switch is faulty Replace the left handlebar switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 68 Replace the lean angle sensor 11 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem s wiring Replace the ECU ...

Page 294: ... L B Y L B Br L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L ...

Page 295: ...STARTING SYSTEM 8 6 4 Main switch 6 Battery 7 Main fuse 8 Starter relay 9 Starter motor 11 Starting circuit cut off relay 32 Neutral switch 33 Clutch switch 36 Engine stop switch 37 Start switch 45 Ignition fuse ...

Page 296: ...l switch is closed The clutch lever is pulled to the handlebar the clutch 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 starting circuit cut off...

Page 297: ...C STARTING SYSTEM 8 8 1 Battery 2 Main fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cut off relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 10 Starter motor 11 Ignition fuse ...

Page 298: ... Recharge or replace the battery 3 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 38 Repair or replace the starter motor 4 Check the starting circuit cut off re lay Refer to CHECKING THE RE LAYS on page 8 65 Replace the relay unit 5 Check the diode Refer to CHECKING THE DI ODES on page 8 66 Replace the relay unit 6 Check the starter relay Refer to CHECKING THE RE LAYS on pa...

Page 299: ...eck the clutch switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the clutch switch 11 Check the start switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the handlebar switch 12 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or repair the starting sys tem wiring The starting system circuit is OK ...

Page 300: ...R W R W R L R L Y R B L W W W R W W W B R W W W GRAY B B R Y R Br R L R W ON OFF OFF R Br R Br Br R BLACK R R R R R R B B B B B B L W Br R R L W Br R Br G Br Br Br R Br Y Br L Br L Br Y Br Y Br Y Br Br R Br Y R B B Y Y Br Y B B BLACK BLACK Y Y B Y B B B B Y Y B B 1 2 3 4 5 6 7 8 9 33 34 35 36 41 42 43 44 45 46 47 48 ...

Page 301: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 6 Battery 7 Main fuse ...

Page 302: ...G AND CHARGING THE BATTERY on page 8 62 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 69 The stator coil is faulty Replace the crank shaft position sensor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 70 Replace the rectifier regulator 5 Check the entire charging...

Page 303: ...CHARGING SYSTEM 8 14 ...

Page 304: ... R L W Br Br R Br G Br Br Br R Br Y Br L Br L Br Y Br Y Br Y Br Br R Br Y R B B Y L B L Y Y R Y L Br R L B Br B R B Br L B B R B BLACK BLACK Y Br Y B B BLACK BLACK Y Y B Y B B B B Y Y B A B Y L Y L B Y L B L Y B L G B Y Y G Y B Y G B G Y G Y B BLACK BLACK G Y B Y G B B BLACK BLACK BLACK B Y G Y L R L B Y L B Br L R Sb Br G Br G R B L W L W Lg Lg Sb Sb Sb 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1...

Page 305: ...LIGHTING SYSTEM 8 16 4 Main switch 6 Battery 7 Main fuse 35 Light switch 38 Headlight relay 39 Headlight 40 Tail brake light 43 Headlight fuse ...

Page 306: ... FUS ES on page 8 61 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 62 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 5 Check the light switch Refer to CHECKING THE SWITCHES on page 8 57 The light switch is faulty Replace the han dlebar switch 6 Chec...

Page 307: ...LIGHTING SYSTEM 8 18 ...

Page 308: ... B Br L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R B Y ...

Page 309: ... Coolant temperature warning light 18 Reverse indicator light 19 Neutral indicator light 20 Reverse switch 21 ECU engine control unit 26 Coolant temperature sensor 27 Speed sensor 31 Fuel pump 32 Neutral switch 40 Tail brake light 41 Rear brake light switch 42 Front brake light switch 44 Signaling system fuse 45 Ignition fuse ...

Page 310: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 62 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Check the condition of each of the sig naling system cir...

Page 311: ... neutral switch 2 Check the diode Refer to CHECKING THE DI ODES on page 8 66 Replace the diode 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the reverse switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the reverse switch 2 Check the entire signaling system wiring R...

Page 312: ...e fuel sender Refer to CHECKING THE FUEL SENDER on page 8 70 Replace the fuel pump 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 71 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRC...

Page 313: ...SIGNALING SYSTEM 8 24 ...

Page 314: ... G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R B Y R Br R L P O R B W L W B...

Page 315: ...LING SYSTEM 8 26 4 Main switch 6 Battery 7 Main fuse 21 ECU engine control unit 26 Coolant temperature sensor 45 Ignition fuse 46 Radiator fan motor 47 Radiator fan motor relay 48 Circuit breaker fan motor ...

Page 316: ...the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 71 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 65 Replace the radiator fan motor relay 6 Check the circuit breaker fan mo tor ...

Page 317: ...COOLING SYSTEM 8 28 NG OK 8 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 25 Properly connect or repair the cooling sys tem wiring Replace the ECU ...

Page 318: ...B Y L B Br L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R...

Page 319: ...r 15 Engine trouble warning light 19 Neutral indicator light 21 ECU engine control unit 22 Ignition coil 23 Spark plug 24 Fuel injector 25 Intake air temperature sensor 26 Coolant temperature sensor 27 Speed sensor 28 Throttle position sensor 29 Intake air pressure sensor 30 Lean angle sensor 31 Fuel pump 32 Neutral switch 36 Engine stop switch 45 Ignition fuse ...

Page 320: ...il it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed EAS27380 SELF DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine trouble warning light and provides the engine wit...

Page 321: ...ature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detected The vehicle has overturned Unable Unable 33 Ignition coil faulty ignition Malfunction detected in the prima ry wire of the ignition coil Unable Unable 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Speed sensor Neutral switch No normal signals a...

Page 322: ...in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27441 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the di agnosti...

Page 323: ...tion meter d01 d70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1 second or longer to automatically increase the diagnostic code numbers 6 Verify the operation of the sensor ...

Page 324: ...throttle position sensor Malfunction in ECU d01 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Improperly installed coolant temperature sensor d06 22 Intake air temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective intake temperature sensor Malfu...

Page 325: ...tem Meter display Checking method d01 Throttle angle Fully closed position 15 20 Check with throttle fully closed Fully opened position 95 100 Check with throttle fully open d03 Pressure difference atmospheric pressure and intake air pressure Displays the intake air pres sure Set the engine stop switch to RUN then operate the throttle while pushing the start switch If the display value changes the...

Page 326: ...arging d21 Neutral switch Shift the transmission Neutral ON In gear OFF d60 EEPROM fault code dis play No history 00 History exists 01 d61 Malfunction history code display No history 00 History exists Fault codes 12 50 If there is more than one code number the display alternates every two sec onds to show all the detect ed code numbers When all code numbers are shown the display repeats the same p...

Page 327: ...trouble warning light also flashes five times Check that the ignition coil actuates five times by watching for the spark Connect an ignition checker d36 Injector Actuates the injector five times in one second inter vals The engine trouble warning light also flashes five times Check that the injector ac tuates five times by listen ing for the operating sound d50 Fuel injection system Actuates the f...

Page 328: ...aft position sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler blue yellow bl...

Page 329: ... any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler black blue black blue pink blue pink blue blue blue 3 Defective int...

Page 330: ...e en gine and oper ating it at idle 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it a...

Page 331: ...coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sens...

Page 332: ...t temperature sensor open or short circuit detect ed Diagnostic code No d06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tempera ture sensor Check the installed area for looseness or pinching Turning the main switch to ON 2 Connections Coolant temperature sensor coupler Main wire harness ECU coupl...

Page 333: ...ue brown white brown white 4 Defective intake air temperature sen sor Execute the diagnostic mode Code No d05 Replace if defective Refer to CHECKING THE IN TAKE AIR TEMPERATURE SENSOR on page 8 73 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No d08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overt...

Page 334: ...ocking condition of the connector and coupler If there is a malfunction repair it and connect the connector or coupler securely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ignition coil connector and ECU coupler orange orange Between ignition coil connector and left handlebar switch cou pler r...

Page 335: ...any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green blue blue 3 Defective lean ang...

Page 336: ...f there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white white black blue black blue 3 Gear for detecting vehicle speed h...

Page 337: ...epair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open circuit in neutral switch lead Repair or replace if there is an open circuit Between neutral switch connec tor and relay unit coupler sky blue sky blue Between relay unit coupler and ECU coupler light green brown black yellow sky blue 3 Faulty ...

Page 338: ...is an open or short circuit Between relay unit coupler and ECU coupler blue red blue red red blue red blue Between relay unit coupler and battery terminal brown green red Between relay unit coupler and handlebar switch coupler red black red black 3 Malfunction or open circuit in fuel in jection system relay Execute the diagnostic mode Code No d09 Replace if defective If there is no malfunction wit...

Page 339: ...E BATTERY on page 8 62 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 11 4 Open or short circuit in the wire har ness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and ignition fuse brown brown Between ignition fuse and ECU coupler brown brown Fault code No 50 Symptom...

Page 340: ... B Br L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R B Y ...

Page 341: ...FUEL PUMP SYSTEM 8 52 4 Main switch 5 Fuel injection system fuse 6 Battery 7 Main fuse 12 Fuel pump relay 21 ECU engine control unit 31 Fuel pump 36 Engine stop switch 45 Ignition fuse ...

Page 342: ...ttery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 57 The engine stop switch is faulty Replace the handlebar switch 5 Check the fuel pump relay Refer to CHECKING THE RE LAYS on page 8 65 Replace the relay unit 6 Check the fuel pump Refer t...

Page 343: ...FUEL PUMP SYSTEM 8 54 ...

Page 344: ...ELECTRICAL COMPONENTS 8 55 EAS27972 ELECTRICAL COMPONENTS 2 3 ...

Page 345: ...y 8 Starter relay 9 Main fuse 10 Circuit breaker fan 11 Fuse box 12 Radiator fan motor relay 13 Headlight relay 14 Relay unit 15 Tail brake light 16 ECU engine control unit 17 Speed sensor 18 Rear brake light switch 19 Neutral switch 20 Reverse switch 21 Coolant temperature sensor 22 Ignition coil 23 Rectifier regulator 24 Radiator fan 25 Headlight ...

Page 346: ...ELECTRICAL COMPONENTS 8 57 EAS27980 CHECKING THE SWITCHES OFF Y R L Y L Y Y R Br L B R B B OFF L B B Br R B OFF ON R Br R Br B B B B 1 2 3 4 5 6 10 7 8 9 ...

Page 347: ...ELECTRICAL COMPONENTS 8 58 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Clutch switch 7 Fuse 8 Reverse switch 9 Neutral switch 10 Rear brake light switch ...

Page 348: ... continuity set the pocket tester 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 cir...

Page 349: ...old 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 a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If a headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcoh...

Page 350: ...t the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set the switches to on to verify if the corre sponding electrical circuits are operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage r...

Page 351: ... battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged as explained in the charging method section If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge st...

Page 352: ...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 a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minute...

Page 353: ... charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the ...

Page 354: ...03112 C 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 R R L W Br R B 1 2 4 3 3 1 2 4 L W L R L G L Y B Y L W R B L B R L Br G Br Sb Lg Result Continuity between 3 and 4 1 Positive battery terminal 2 Negat...

Page 355: ...erminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Pocket tester 90890 03112 Analog pocket tester YU 03112 C L Y G B Y 5 3 4 1 2 Continuity P...

Page 356: ...Measure the secondary coil resistance EAS28930 CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 3 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally Pocket tester 90890 03112 Analog pocket tester YU 03112 C Primary c...

Page 357: ...r as shown b Measure the crankshaft position sensor re sistance EAS28130 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 pocket tester DC 20 V to the lean angle sensor coupler as shown Ignition checker 90890 06754 Opama pet 4000 spark checker YM ...

Page 358: ...ry lead otherwise the jumper lead may burn This check is 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 AC magneto coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the crank shaft position sensor stator coil assembly a Connect the po...

Page 359: ...ness 2 Drain Fuel from the fuel tank 3 Remove Fuel pump assembly from the fuel tank 4 Check Fuel sender current Out of specification Replace the fuel pump assembly a Connect the pocket tester DC 5A and bat tery to the fuel sender terminal as shown Charging voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red 1 Negative tester probe bl...

Page 360: ... CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS1S3L042 CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 1 Remove Radiator fan motor circuit breaker from the wire harness a Fuel level 79 5 mm 3 13 in Output vo...

Page 361: ...perature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get ...

Page 362: ...lace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown b Set the main switch to ON c Measure the intake air pressure sensor out put voltage EAS28420 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air t...

Page 363: ...e sensor terminal as shown b Measure the intake air temperature sensor resistance Intake air temperature sensor re sistance 2 21 2 69 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe black white 2 Br W B W 1 2 ...

Page 364: ...ELECTRICAL COMPONENTS 8 75 ...

Page 365: ...G 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 SHOCK ABSORBER ASSEMBLY 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 366: ...ollover valve hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Vacuum leak Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat...

Page 367: ...ft drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum ...

Page 368: ...ake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS1S3L012 FAULTY SHOCK ABSORBER ASSEMBLY Leaking oil Bent damaged or rusty damper rod Cracked or damaged shock absorber Damaged oil seal lip Malfunction Fatigue o...

Page 369: ...dlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light Faulty battery Too many electrical accessories Incorrectly adjusted rear brake light switch Incorrect connection Broken tail brake light LED Tail brake light broke...

Page 370: ...ssure sensor 30 Lean angle sensor 31 Fuel pump 32 Neutral switch 33 Clutch switch 34 Handlebar switch 35 Light switch 36 Engine stop switch 37 Start switch 38 Headlight relay 39 Headlight 40 Tail brake light 41 Rear brake light switch 42 Front brake light switch 43 Headlight fuse 44 Signaling system fuse 45 Ignition fuse 46 Radiator fan motor 47 Radiator fan motor relay 48 Circuit breaker fan moto...

Page 371: ......

Page 372: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 373: ... L R R L L R L W G Y G W G W G W G W Br L Y Sb Y R P L Y P L B L L Y B L L W B L L Y G L B LY G Lg L W B L Sb Br G Br G B W G Y O G R B L W L W Lg Lg Sb Sb Sb A Br G G Y B W O G Lg Br Br G G Y Lg B W Br O G Y G B L L B Y Lg R L L B Sb R B L G L Y Br L W L R L W Br G B O O Y L B L BLACK P L B L L GRAY B W B R L O G B W O G R L L W O Lg Br W Sb B Y G G Y G W B Y W L R P L B W L Y Y B L L R B Y R Br ...

Page 374: ...ACK BLACK B A B BLACK BLACK BLACK BLACK BLACK A BLACK GRAY BLACK GRAY GRAY GRAY WIRE HARNESS SUB WIRE HARNESS A BLACK BLACK WIRE HARNESS FRONTBRAKELIGHTSWITCH SUB WIREHARNESS B 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

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