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Yamaha ROADLINER XV19SW, Service Manual


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FRONT BRAKE

4-41

• Brake fluid delivery passages

(brake master cylinder body)
Obstruction 

→

 Blow out with compressed air.

2. Check:

• Brake master cylinder kit

Damage/scratches/wear 

→

 Replace.

3. Check:

• Brake master cylinder reservoir

Cracks/damage 

→

 Replace.

• Brake master cylinder reservoir diaphragm

Damage/wear 

→

 Replace.

4. Check:

• Brake hose

Cracks/damage/wear 

→

 Replace.

EAS22520

ASSEMBLING THE FRONT BRAKE MASTER 
CYLINDER

WARNING

EWA13520

• Before installation, all internal brake com-

ponents should be cleaned and lubricated 
with clean or new brake fluid.

• Never use solvents on internal brake com-

ponents.

EAS22530

INSTALLING THE FRONT BRAKE MASTER 
CYLINDER

1. Install:

• Front brake master cylinder “1”
• Front brake master cylinder holder “2”

NOTE:

• Align the end of the brake master cylinder hold-

er with the punch mark “a” on the handlebar.

• First, tighten the rear bolt, then the front bolt.

2. Install:

• Copper washers 
• Front brake hose “1”
• Front brake hose union bolt “2”

WARNING

EWA13530

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-45.

NOTE:

• Install the brake hose at a right angle to the 

front brake master cylinder as shown in the il-
lustration.

• While holding the brake hose, tighten the union 

bolt.

• Turn the handlebar to the left and right to make 

sure the brake hose does not touch other parts 
(e.g., wire harness, cables, leads). Correct if 
necessary.

3. Fill:

• Brake master cylinder reservoir

(with the specified amount of the recom-
mended brake fluid)

 

Recommended fluid

DOT 4

T

 

R

.

 

Front brake master cylinder hold-
er bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

1

T

 

R

.

 

Front brake hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

 

Recommended fluid

DOT 4

2

a

1

New

10–30˚

1

2

Summary of Contents for ROADLINER XV19SW

Page 1: ...anuals have been CycleHippied Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data If you obtained this manual from a source other than...

Page 2: ...SERVICE MANUAL XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C LIT 11616 20 40 1D7 28197 11...

Page 3: ...C SERVICE MANUAL 2006 by Yamaha Motor Corporation U S A First edition July 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S...

Page 4: ...ded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of it...

Page 5: ...ge 1 Sub 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 s...

Page 6: ...14 15 16 LT New T R 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 oi...

Page 7: ......

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

Page 9: ......

Page 10: ...F THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 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 PL...

Page 11: ...E IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the rider seat...

Page 12: ...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 plac...

Page 13: ...ming are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed sen...

Page 14: ...the fuel reserve a clock a self diagnosis device a brightness control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET switches except for setting the brightness control mode...

Page 15: ...The fuel gauge does not indicate the correct fuel level for the first 5 km h 3 mi h after refu eling Odometer tripmeter and clock modes Push the SELECT switch to switch the display between the odomete...

Page 16: ...d as soon as possible in order to avoid engine damage Brightness control mode The brightness can be adjusted for the following the multi function meter unit panel item num ber 1 the LCD item number 2...

Page 17: ...RES 1 7 7 Push the SELECT switch The odometer tripmeter clock display will re turn to the prior mode 1 Speedometer needle 2 Tachometer needle 3 Fuel gauge needle 4 Item number 5 Brightness level 4 2 3...

Page 18: ...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...

Page 19: ...ase Oil bearings liberally when installing if appropri ate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassemb...

Page 20: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5...

Page 21: ...t provided below to avoid any mistakes NOTE 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 page...

Page 22: ...rench 90890 01403 Spanner wrench YU 33975 3 26 4 71 Damper rod holder 90890 01460 4 64 4 66 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 64 4 66 Fork seal driver 90890 01442 Adjustabl...

Page 23: ...de reamer 6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 40 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 46 Universal clutch holder 90890 04086 YM 91042 5 60 5 65 Sheave holder 9...

Page 24: ...set 90890 06756 6 12 Pressure gauge 90890 03153 6 12 Fuel pressure adapter 90890 03176 YM 03176 6 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 6 12 Ignition chec...

Page 25: ...SPECIAL TOOLS 1 15...

Page 26: ...13 TIGHTENING TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS...

Page 27: ...19CTMW 4P14 USA XV19CTMW 4P16 CDN XV19CTMWC 4P15 California Dimensions Overall length 2580 mm 101 6 in Overall width 1100 mm 43 3 in Overall height XV19S C XV19 C XV19M C 1100 mm 43 3 in XV19CTS C XV1...

Page 28: ...oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt With oil filter cartridge replacement 4 90 L 5 18 US qt 4 31 Imp qt Oil pressure hot 60 0 kPa 900 r min 8 7 psi 900 r min 0 60 kgf cm 90...

Page 29: ...5 000 25 021 mm 0 9843 0 9851 in Camshaft journal diameter crankcase side 24 957 24 980 mm 0 9826 0 9835 in Camshaft to crankcase clearance 0 020 0 064 mm 0 0008 0 0025 in Camshaft cover hole inside d...

Page 30: ...0 36 10 mm 1 4134 1 4213 in Valve head diameter A exhaust 30 90 31 10 mm 1 2165 1 2244 in Valve seat width C intake 1 10 1 30 mm 0 0433 0 0512 in Limit 2 0 mm 0 08 in Valve seat width C exhaust 1 10 1...

Page 31: ...K1 exhaust 16 58 N mm 94 67 lb in 1 69 kgf mm Spring rate K2 exhaust 21 98 N mm 125 51 lb in 2 24 kgf mm Installed compression spring force intake 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Instal...

Page 32: ...0 9073 in Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Limit 0 074 mm 0 00291 in Pi...

Page 33: ...0012 0 0024 in Limit 0 10 mm 0 0039 in Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Operation Left hand operation Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 1...

Page 34: ...Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 1D7 MITSUBISHI Maximum consumption amperage 5 5 A Output pressure 441 0 637 0 kPa 63 9 92 4 psi 4 41 6 37...

Page 35: ...FICATIONS 2 9 Idling condition Engine idling speed 850 950 r min Intake vacuum 31 3 35 3 kPa 9 3 10 4 inHg 235 265 mmHg Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 4 0 6 0 mm...

Page 36: ...in Front tire Type Tubeless Size 130 70R18M C 63H Manufacturer model DUNLOP D251F Manufacturer model BRIDGESTONE G851 RADIAL G Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 190 60R17M C...

Page 37: ...mm 0 22 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Maste...

Page 38: ...6 50 N mm 1007 82 lb in 18 00 kgf mm Spring stroke K1 0 0 50 0 mm 0 00 1 97 in Optional spring available No Enclosed gas air pressure STD 0 98 MPa 139 4 psi 9 8 kgf cm Spring preload adjusting positio...

Page 39: ...to Model manufacturer F4T38971 MITSUBISHI Standard output 14 0 V 32 0 A 5000 r min Stator coil resistance 0 112 0 168 Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer...

Page 40: ...08 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Horn Horn type Eddy Quantity 2 pcs Model manufacturer YP 12 NIKKO...

Page 41: ...sistance at 100 C 898 4 1098 0 Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Auxiliary DC connector fuse 3 0 A ECU fuse 10 0 A Fu...

Page 42: ...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 speci...

Page 43: ...7 2 ft lb Left balancer weight bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Left balancer idle gear shaft bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Camshaft driven gear bolt M10 1 60 Nm 6 0 m kg 43 ft lb Camshaft driv...

Page 44: ...Locknut EXUP cable M6 2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear exhaust pipe joint cover bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Muffler and muffler bracket b...

Page 45: ...rter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Primary drive gear bolt M12 1 100 Nm 10 0 m kg 72 ft lb Clutch boss nut M20 1 105 Nm 10 5 m kg 75 ft lb Stake Clutch spring plate retainer bolt M6 6 8 Nm...

Page 46: ...Nm 1 0 m kg 7 2 ft lb Oil tank bracket bolt M8 2 28 Nm 2 8 m kg 20 ft lb Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stopper lever bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Crankshaft positi...

Page 47: ...TIGHTENING TORQUES 2 21 Cylinder head tightening sequence 3 1 2 4 A B 3 1 2 4 A Front cylinder B Rear cylinder...

Page 48: ...de M12 1 105 Nm 10 5 m kg 75 ft lb Engine bracket nut front upper side M10 4 53 Nm 5 3 m kg 38 ft lb Engine cross member bracket bolt M10 2 30 Nm 3 0 m kg 22 ft lb Engine bracket nut left rear low er...

Page 49: ...tening torque M30 1 18 Nm 1 8 m kg 13 ft lb See NOTE Hose guide and lower handlebar holder nut M10 2 32 Nm 3 2 m kg 23 ft lb Front brake master cylinder hold er bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Fron...

Page 50: ...8 2 16 Nm 1 6 m kg 11 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose union bolt front brake caliper side M10 2 32 Nm 3 2 m kg 23 ft lb Rear brake caliper bolt M10 2 27 N...

Page 51: ...ster cylinder bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder bracket and frame bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder cover bolt M8 2 16 Nm 1 6 m kg 11 ft lb Brake...

Page 52: ...Rear shock absorber locknut M50 1 30 Nm 3 0 m kg 22 ft lb Windshield holder bracket as sembly bolt M8 4 30 Nm 3 0 m kg 22 ft lb Windshield holder nut M8 4 23 Nm 2 3 m kg 17 ft lb Windshield bracket b...

Page 53: ...driven gear housing Flange bolts left balancer drive gear and right balancer driven gear Camshaft cam lobes and camshaft journals Flange bolt camshaft gear Valve push rod end balls Valve stems intake...

Page 54: ...ve pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Stator co...

Page 55: ...moving parts Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Shift pedal pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point...

Page 56: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 22 21 19 18 20 23 17 16 15 11 10 14 13 9 8 12 14 7 6 5 4 2 3 1 9 8...

Page 58: ...8 Front cylinder head cover 9 Rear cylinder head cover 10 Rear cylinder camshaft 11 Front cylinder camshaft 12 Rear valve lifter case 13 Front valve lifter case 14 Push rod 15 Crankshaft 16 Camshaft...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS E A A B B E E D D C C A A B E D D B 2 9 3 8 1 10 4 5 6 7 8 11 4 5...

Page 60: ...EM CHART AND DIAGRAMS 2 34 1 Oil tank 2 Dipstick 3 Oil pipe 2 4 Oil delivery pipe 1 5 Oil filter cartridge 6 Oil delivery pipe 2 7 Oil pipe 3 8 Oil pipe 4 9 Oil pipe 5 10 Oil strainer oil tank 11 Oil...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 D D B B D D C C A A B C C B 3 2 1 3 4 6 7 6 7 5...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Oil pipe 1 5 Crankshaft 6 Oil pipe F mark 7 Oil pipe R mark...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 A A A A 1 3 2 4...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pipe 1 2 Oil pump 3 Oil strainer crankcase 4 Joint pipe...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 A 1 2 3 4...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil strainer crankcase 4 Oil pump A To the oil filter cartridge...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 A A A 1 5 5 1 3 2 4 B B B B...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil pipe 5 2 Transfer gear oil pump 3 Oil strainer transfer gear case 4 Middle drive shaft 5 Oil strainer oil tank A From the oil pump...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 1 2...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Transfer gear oil pump 2 Middle driven shaft...

Page 71: ...CABLE ROUTING 2 45 EAS20430 CABLE ROUTING C D F F C D B B C C D D F F A E A E B B 1 1 1 1 2 3 4 5 5 5 5 5 6 6 6 6 7 7 7 7 8 9 10 11 A B C E F G D...

Page 72: ...r switch leads Either lead can be routed on top B 70 mm 2 76 in C 5 25 D 10 30 E Fasten the rear brake light switch lead with the plastic locking tie Face the end of the plastic locking tie inward and...

Page 73: ...CABLE ROUTING 2 47 B B C D D E E B B G G F F E E D D A A C F F 1 1 1 1 2 2 2 2 2 3 3 4 4 5 6 6 7 8 8 9 12 G G 3 B G J H I A C D E F K L 10 11...

Page 74: ...the headlight leads front turn signal position light leads and accessory light lead with the holders along the side of the headlight housing E Place the headlight leads front turn signal position ligh...

Page 75: ...E B B I F F A B C D E F G H I J K L M S 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 14 15 16 17 21 26 F F G G D D H H H H K I B B C C Z 3 3 20 23 24 25 S W V T T T AH 18 19 27 AE AD AF U AB AA AC 28 Y...

Page 76: ...ront brake hose H Make sure that the wire harness is not twisted between the fuel tank and the headlight assembly I Position the cylinder 2 left and right spark plug leads sub wire harness 2 coupler a...

Page 77: ...A A B B C C D D E G G F H H F A B C D E F G H I J K L M N N O Q R U S T O Q R S V Y Z 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15 16 17 18 15 16 18 34 18 35 19 20 21 22 23 24 24 25 26 27 28 29 30 31...

Page 78: ...itch lead and sidestand switch lead to the inside of the frame boss N Fasten the starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead with the plastic locking tie Face...

Page 79: ...CABLE ROUTING 2 53...

Page 80: ...e upward and then cut off the excess end of the tie H Connect the ECU couplers and then fasten the ECU with the band I Fasten the fuel return hose fuel return pipe to sub fuel tank with the plastic lo...

Page 81: ...CABLE ROUTING 2 55 C C B C C A A B D E C L N 1 2 3 4 4 5 5 6 6 7 7 4 5 6 7 8 8 8 9 10 11 11 11 12 14 13 15 16 17 18 19 20 21 22 26 27 A B F G H I J K L M O P Q R S T U V W X 21 23 24 25 28 H F 24 G...

Page 82: ...Align the ends of the hose clamp with the white paint mark on the fuel return hose F Align the paint marks on the hoses with the hose joint as shown in the illustration G Fasten the fuel tank breather...

Page 83: ...CABLE ROUTING 2 57 C C B A B A C C A B D C E F H G I J 1 2 3 4 5 4 5 6 7 8 9 10 11 12 13 11 13 14 15 16 17 18 19 20 22 7 11 11 13 13 11 21 K...

Page 84: ...take air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward Face the ends of the hose clamp forward C Fasten the ca...

Page 85: ...CABLE ROUTING 2 59 A B B A A B B C D E F G H I J 1 2 3 4 4 5 6 7 8 8 8 9 9 9 10 10 10 11 9 10 12 13 14 15 16 17 18 19 B...

Page 86: ...ke manifold assembly completely onto the intake manifold making sure to face the green paint mark on the hose to the left Face the ends of the hose clamp outward angled 45 forward D Install the cylind...

Page 87: ...CABLE ROUTING 2 61...

Page 88: ...KING THE CYLINDER HEAD BREATHER HOSE 3 17 CHECKING THE OIL TANK BREATHER HOSE 3 17 CHECKING THE EXHAUST SYSTEM 3 17 CHECKING THE CANISTER for California only 3 18 ADJUSTING THE EXUP CABLES 3 18 CHASSI...

Page 89: ...ELECTRICAL SYSTEM 3 31 CHECKING AND CHARGING THE BATTERY 3 31 CHECKING THE FUSES 3 31 REPLACING THE HEADLIGHT BULBS 3 31 ADJUSTING THE HEADLIGHT BEAMS 3 32...

Page 90: ......

Page 91: ...cks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance wh...

Page 92: ...Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leakage Replace if necessary 18 Shock...

Page 93: ...to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch rele...

Page 94: ...rance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature W...

Page 95: ...bolts do not scratch the rocker arms or other engine parts 11 Measure Valve clearance Out of specification Adjust Piston 1 TDC rear cylinder a Turn the crankshaft counterclockwise b When piston 1 is a...

Page 96: ...earance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b with the tappet adjusting tool 4 u...

Page 97: ...suitable stand 2 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1 Fuel tank Refer to FUEL TANK on...

Page 98: ...en two throttle bodies should not exceed 1 33 kPa 10 mmHg 8 Stop the engine and remove the measuring equipment 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on pag...

Page 99: ...plug CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type I...

Page 100: ...iming mark accessing screw 3 4 Connect Timing light 1 Tachometer 5 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...

Page 101: ...ed Do not screw the dipstick in when inspecting the oil level CAUTION ECA13380 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not a...

Page 102: ...Replace 9 Install Engine oil drain bolt oil tank along with the gasket 10 Install Engine oil drain bolts crankcase along with the gaskets 11 Fill Oil tank with the specified amount of the recom mended...

Page 103: ...oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 95 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gal...

Page 104: ...r to CHECKING THE TRANSFER GEAR OIL LEVEL on page 3 13 10 Install Exhaust pipes Muffler Refer to ENGINE REMOVAL on page 5 1 EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the vehicle on a level surf...

Page 105: ...siderably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose...

Page 106: ...e 4 1 EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Rider seat Rider seat bracket assembly Refer to GENERA...

Page 107: ...hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on pag...

Page 108: ...Install Horn 1 Refer to THROTTLE BODIES on page 6 6 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation a Turn the main switch to ON b Check that the E...

Page 109: ...and check that the projection c on the EXUP valve pulley contacts the stoppers fully open and fully closed positions then stops between the lines d on the cable holder 5 Install EXUP valve pulley cov...

Page 110: ...cle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance CAUTION ECA13510 After adjusting the brake pedal position mak...

Page 111: ...e a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal 4 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21250 CHECKING THE FRONT BRAKE PA...

Page 112: ...GHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect st...

Page 113: ...ress down the brake pedal and hold it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake...

Page 114: ...gine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on...

Page 115: ...rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 WARNING EWA12800 Always use a new gasket EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehic...

Page 116: ...lower bearings Refer to STEERING HEAD on page 4 69 e Install the rubber washer 3 f Install the upper ring nut g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary...

Page 117: ...knut 2 b Turn the adjusting ring 3 in direction a or b c Tighten the locknut to specification CAUTION ECA13600 Always tighten the locknut against the ad justing nut and torque it to specification EAS2...

Page 118: ...he correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is no...

Page 119: ...E WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has...

Page 120: ...1720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal mo...

Page 121: ...ght coupler 1 b Remove Headlight bulb 2 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down c Install Headli...

Page 122: ...oughly clean it with a cloth moistened with alcohol or lacquer thinner f Attach Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover 7 Install Headlight assembly 8 Connect...

Page 123: ...ELECTRICAL SYSTEM 3 33 a b 1...

Page 124: ...ECKING THE REAR WHEEL 4 28 CHECKING THE REAR BRAKE CALIPER BRACKET 4 28 CHECKING THE REAR WHEEL DRIVE HUB 4 29 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 29 ASSEMBLING THE REAR WHEEL 4 29 ADJUSTIN...

Page 125: ...EGS 4 64 DISASSEMBLING THE FRONT FORK LEGS 4 64 CHECKING THE FRONT FORK LEGS 4 65 ASSEMBLING THE FRONT FORK LEGS 4 65 INSTALLING THE FRONT FORK LEGS 4 68 STEERING HEAD 4 69 REMOVING THE LOWER BRACKET...

Page 126: ......

Page 127: ...ket left and right 2 4 Windshield brace left and right 2 5 Windshield screen 1 6 Windshield holder bracket assembly left and right 2 For installation reverse the removal proce dure 1 6 T R 23 Nm 2 3 m...

Page 128: ...ent it from falling when removing ET1D71045 ASSEMBLING THE WINDSHIELD 1 Install Windshield lock 1 NOTE Align the projection a on the lock 1 with the slot b in the windshield bracket 2 ET1D71040 INSTAL...

Page 129: ...GENERAL CHASSIS 4 3 c Insert the key into the windshield lock turn it counterclockwise until it stops to lock the fas tener and then remove the key 1 Lock 2 Fastener 2 1 1...

Page 130: ...on the sidebags Polish the dry leather with a soft cloth and then treat with Yamaha Mink Oil or another high quality leather protectant for increased water resistance 2 Backrest assembly 1 3 Backrest...

Page 131: ...t b in the left backrest lower bracket 2 2 Install Backrest lower brackets 1 Backrest upper bracket 2 Backrest plate NOTE Before tightening the bolts 3 to specification temporarily install the backres...

Page 132: ...e sure that the lever hook 1 on each side is secure ly fit over its holder 2 WARNING EW1D71017 Both lever hooks must be securely fitted over their holder If the backrest is loose a passenger might los...

Page 133: ...g bracket brace 1 3 Sidebag bracket left and right 2 NOTE Remove only one sidebag bracket at a time If both brackets are removed at the same time the rear fender will fall 4 O2 sensor lead guide 1 NOT...

Page 134: ...D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1 Check Sidebag bracket spring nut height a Out of specification Adjust 2 Check Sidebag bracket spring nuts Damage Replace Sidebag bracket spring nut he...

Page 135: ...ssembly 1 6 Right side cover 1 7 Left side cover 1 8 Seat lock cable assembly 1 For installation reverse the removal proce dure 1 6 2 4 5 7 8 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib...

Page 136: ...Headlight lens unit 1 7 Front left turn signal position light coupler 1 Disconnect 8 Front right turn signal position light coupler 1 Disconnect 9 Wire harness stopper bracket 1 10 Left handlebar swit...

Page 137: ...nit 1 3 Coupler tray 1 4 Negative terminal cover 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 Sub wire harness 1 1 Disconnect 10 Main fuse...

Page 138: ...elay 1 18 Turn signal relay 1 19 Plastic locking tie 2 20 Battery box 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks 13 18 17 16 15 19 14...

Page 139: ...1 intake air pressure sensor 1 6 Cylinder 1 intake air pressure sensor bracket 1 7 Cylinder 2 intake air pressure sensor coupler 1 Disconnect 8 Cylinder 2 intake air pressure sensor hose 1 Disconnect...

Page 140: ...screw 2 Loosen 17 Air filter case 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks 15 9 7 8 14 16 11 4 3 12 13 16 5 6 1 17 2 10 T R...

Page 141: ...ket 1 7 Front fender 1 8 Reflector 2 9 Reflector bracket 2 10 Front brake caliper 2 11 Front wheel axle pinch bolt 1 Loosen 12 Front wheel axle 1 13 Front wheel 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm...

Page 142: ...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 LT LT LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m...

Page 143: ...FRONT WHEEL 4 17 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 1 3 LS LS New New...

Page 144: ...inch bolt 1 4 Remove Front brake calipers NOTE Do not apply the brake lever when removing the brake calipers 5 Elevate Front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is...

Page 145: ...011 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil sea...

Page 146: ...Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is bala...

Page 147: ...ose guide bracket NOTE Temporarily tighten the front fender bolts Apply locking agent LOCTITE to the threads of the front fender bolts 8 Install Front fender stay rod 1 Left front fender stay 2 Right...

Page 148: ...FRONT WHEEL 4 22...

Page 149: ...er seat Passenger seat Tool kit tray Refer to GENERAL CHASSIS on page 4 1 1 Sub wire harness 1 coupler 1 Disconnect 2 Rear fender bracket 2 3 Dowel pin 4 4 Rear fender assembly 1 For installation reve...

Page 150: ...r 1 3 Rear brake pad 2 4 Brake pad spring 2 5 Drive belt adjusting locknut 2 Loosen 6 Drive belt adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Right drive belt pull...

Page 151: ...tion reverse the removal proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb 12 9 4 2 4 3 1...

Page 152: ...to remove Q ty Remarks 1 Rear brake disc cover 1 2 Rear brake disc 1 3 Rear wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 8 Bearing 1 9 Collar 1 10 Bearing 1 11 Rear whe...

Page 153: ...4 27 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure 6 4 3 2...

Page 154: ...move the drive belt from the rear wheel pulley EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 18 EAS22090 CHECKING THE REAR WH...

Page 155: ...NT WHEEL on page 4 19 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance...

Page 156: ...t slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 6 Tighten Rear wheel axle nut 7 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly T R Rear wheel axle...

Page 157: ...e front brake calipers 1 Brake hose holder 1 2 Reflector 1 3 Reflector bracket 1 4 Front brake caliper 1 5 Brake pad clip 2 6 Brake pad pin 1 7 Brake pad spring 1 8 Brake pad 2 9 Brake pad shim 2 For...

Page 158: ...cylinder reservoir diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Brake light switch connector 2 Disconnect 7 Brake light switch 1 8 Front brake hose union bolt 1...

Page 159: ...ng 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 pr...

Page 160: ...rain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Brake hose holder 1 2 Front brake hose union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Reflector 1 6 Reflector bracket 1 7 Front...

Page 161: ...Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake caliper piston 4 7 Brake...

Page 162: ...ve Front wheel Refer to FRONT WHEEL on page 4 15 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake d...

Page 163: ...a set 2 Install Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tigh...

Page 164: ...tem 1 Remove Brake hose holder 1 Front brake hose union bolt 2 Copper washers 3 Front brake hose 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 D...

Page 165: ...s as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following pr...

Page 166: ...aces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check Brake fluid level Below the mi...

Page 167: ...d of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the rear bolt then the front bolt 2 Install Copper washers Front brake hose 1 Front brake hose union bolt 2...

Page 168: ...reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always...

Page 169: ...ake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure 1 2 4 4 3 1 T...

Page 170: ...1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake master cylinder cover 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake light switch 1 11 Ri...

Page 171: ...al proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 10 12 15 9 6 8 13 14 11 5 2 3 4 7 R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg...

Page 172: ...cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder body 1 For assembly reverse...

Page 173: ...in Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation re...

Page 174: ...bling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston seal 2 3 Bleed screw 1 For assembly reverse the disassembly pro cedure 2 1 3 T R 6 N...

Page 175: ...page 4 23 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 Refer to CHECKING THE FRONT BRAKE D...

Page 176: ...n page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers...

Page 177: ...ke com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Ins...

Page 178: ...e fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the prope...

Page 179: ...n 2 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriora...

Page 180: ...Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 20 7 Adjust Rear brake light operation...

Page 181: ...cylinder assembly 1 6 Throttle cable holder 1 7 Right handlebar switch 1 8 Throttle cable 2 9 Grip end 2 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect 12 Clutch master cylinder holder 1 13...

Page 182: ...tion reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 5 13 18 14 17 15 12 14 11 7 9 4 7 8 19 2 2 3 16 9 1 6 10 LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2...

Page 183: ...e cable decelerator cable 1 to the right handlebar switch 2 NOTE Rotate the right handlebar switch and screw it onto the end of the throttle cable 3 Pass the left and right handlebar switch leads thro...

Page 184: ...ebar switch 1 Grip end 2 NOTE Align the projection a on the right handlebar switch with the hole b in the handlebar There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the...

Page 185: ...HANDLEBAR 4 59 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in...

Page 186: ...5 1 Upper bracket cover 1 2 Upper bracket pinch bolt 4 Loosen 3 Cap bolt 1 Loosen 4 Steering stem nut 1 5 Upper bracket 1 6 Upper front fork cover 1 7 Upper front fork cover spacer 1 8 Upper front for...

Page 187: ...ing the front fork legs Order Job Parts to remove Q ty Remarks 1 5 6 7 8 11 3 12 9 2 10 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 115 Nm 11 5 m kg 85 ft lb R 16 Nm 1 6 m kg 11 ft Ib R 1...

Page 188: ...1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Oute...

Page 189: ...ube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 23 Nm 2 3 m kg 17 ft...

Page 190: ...n ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver CAUTION ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer NOTE While holding the dampe...

Page 191: ...leg do not allow any foreign ma terial to enter the front fork 4 Check Cap bolt O ring Damage wear Replace EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front...

Page 192: ...ECA14220 Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with...

Page 193: ...e fork spring Out of specification Correct NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 12 Install Spring 1...

Page 194: ...e lower front fork cover nut 2 6 Tighten Steering stem nut Cap bolt Upper bracket pinch bolts NOTE Tighten the upper bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alter...

Page 195: ...t and throttle cable guide 1 2 Front brake hose guide 1 3 Front brake hose joint 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Lower bracket 1 9 Upper bearing cover 1 10...

Page 196: ...val proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 8 1 3 2 12 11 13 13 10 9 7 6 5 4 LS LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib T R 10 Nm 1 0 m k...

Page 197: ...ove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new beari...

Page 198: ...3 25 3 Install Front brake hose joint 1 Front brake hose guide 2 NOTE Make sure that the projection a on the lower bracket contacts the side b of the front brake hose joint 1 Align the projection c o...

Page 199: ...sen Refer to ENGINE REMOVAL on page 5 1 1 Horn 1 coupler 1 Disconnect 2 Horn 1 1 3 Passenger footrest left and right 2 For XV19S C XV19 C XV19M C only 4 O2 sensor lead guide 1 NOTE Pass the O2 sensor...

Page 200: ...l proce dure Removing the rear shock absorber assembly and swingarm Order Job Parts to remove Q ty Remarks 6 2 7 10 9 8 6 T R 59 Nm 5 9 m kg 43 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 7 Nm 0 7 m kg 5...

Page 201: ...nnecting arm 2 6 O ring 4 7 Spacer 1 8 Bushing 4 9 Self locking nut Washer Bolt 1 2 1 10 Rear shock absorber 1 11 Relay arm 1 12 Oil seal Spacer Bearing 2 1 1 13 Oil seal Spacer Bearing 2 1 2 14 Colla...

Page 202: ...SORBER ASSEMBLY AND SWINGARM 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable sta...

Page 203: ...m Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Bushings Damage wear Replace 4 Check Spacers Collars Damage scratches Replace EAS23360 CHECKING THE SWINGARM 1 Check Swi...

Page 204: ...b in the bushings are within the areas shown in the illus tration 5 Install Connecting arms Rear shock absorber assembly to relay arm Relay arm to the swingarm NOTE Be sure to face the FWD mark a on...

Page 205: ...it does not drop down 5 Tighten Pivot shaft nut Engine mounting nut rear lower side Connecting arm nut front side 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 T R Con...

Page 206: ...over 1 2 Lead cover 1 3 Stator coil coupler 1 Disconnect 4 Rectifier regulator coupler 1 Disconnect 5 Rectifier regulator 1 6 Drive pulley cover 1 7 Slider 2 8 Dowel pin 2 9 Transfer gear case bracket...

Page 207: ...he drive belt and drive pulley Order Job Parts to remove Q ty Remarks LT 7 8 13 12 11 10 9 6 1 2 4 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib R 53 Nm 5 3 m kg 38 ft Ib T R 10 Nm 1 0 m kg...

Page 208: ...f with clean water Then let the drive belt thoroughly dry 2 Check Drive belt CAUTION ECA14690 To protect the drive belt from damage han dle it with care The drive belt can not be bent smaller than 127...

Page 209: ...L on page 4 23 4 Tighten Drive pulley nut NOTE When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move Stake the drive pulley nut 1 at a cutout a in the mi...

Page 210: ...NG 5 26 CHECKING THE OIL DELIVERY PIPE 5 27 INSTALLING THE CAMSHAFTS 5 27 BLEEDING A VALVE LIFTER 5 29 INSTALLING THE VALVE LIFTERS 5 30 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 31 INSTALLING THE CY...

Page 211: ...ALLING THE CLUTCH MASTER CYLINDER 5 67 REMOVING THE CLUTCH RELEASE CYLINDER 5 68 CHECKING THE CLUTCH RELEASE CYLINDER 5 68 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 68 INSTALLING THE CLUTCH RELEASE CYL...

Page 212: ...RELIEF VALVE 5 98 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 5 98 CHECKING THE OIL STRAINER 5 99 ASSEMBLING THE OIL PUMP 5 99 INSTALLING THE OIL PUMP 5 100 CRANKSHAFT 5 101 REMOVING THE CONNECTI...

Page 213: ...er bracket 1 8 Muffler 1 9 Gasket 1 10 Rear exhaust pipe cover 1 11 Rear exhaust pipe 1 12 Gasket 2 13 O2 sensor 1 14 Front exhaust pipe 1 5 8 9 10 3 11 12 14 15 1 2 12 13 6 7 4 R 10 Nm 1 0 m kg 7 2 f...

Page 214: ...10 3 11 12 14 15 1 2 12 13 6 7 4 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 4...

Page 215: ...ge 4 80 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 Starter motor Refer to ELECTRIC STARTER on page 5 77...

Page 216: ...heel side 1 17 Shift pedal shaft 1 18 Sidestand switch 1 19 Sidestand 1 For installation reverse the removal proce dure Removing the cylinder 1 ignition coils and sidestand Order Job Parts to remove Q...

Page 217: ...pin on the toe side with the mark b on the heel side 2 Install Shift pedal assembly 1 NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal 3 Adjust Shift rod length Refer to...

Page 218: ...5 Oil cooler bracket 1 6 Oil filter bolt 1 7 Oil filter bracket 1 For installation reverse the removal proce dure LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 f...

Page 219: ...eck Oil cooler fins Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace NOTE Straighten any flattened fins with a thin flathead screwdriver 2 Check Oil cooler...

Page 220: ...1 5 Lead holder bracket 1 6 Wire harness guide 1 7 Throttle cable guide 1 8 Starter motor lead 1 9 Horn 2 lead 1 10 Rear brake light switch lead 1 11 Sidestand switch lead 1 12 Crankshaft position sen...

Page 221: ...llation reverse the removal proce dure Disconnecting the leads Order Job Parts to remove Q ty Remarks 3 2 7 1 10 8 9 5 11 6 LT LT R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg...

Page 222: ...ng nut front upper side 1 8 Engine mounting bolt front upper side 1 9 Engine cross member bracket bolt 2 10 Engine cross member bracket 1 11 Engine bracket nut front upper side 4 12 Engine bracket bol...

Page 223: ...ide 1 23 Engine mounting bolt rear lower side 1 24 Washer 1 25 Engine 1 For installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks R 105 Nm 10 5 m kg 75...

Page 224: ...ricate the engine mounting bolt front lower side threads and nut with engine oil Apply locking agent LOCTITE to the threads of the engine mounting bolts left upper side Do not fully tighten the bolts...

Page 225: ...ELT DRIVE on page 4 80 9 Tighten Engine bracket nut front upper side 3 Engine cross member bracket bolts 5 Engine mounting nut front upper side 7 T R Engine mounting nut rear lower side 98 Nm 9 8 m kg...

Page 226: ...park plug cap 4 Disconnect 2 Spark plug 4 3 Shift pedal assembly 1 4 Damper cover 1 5 Damper 1 6 Timing mark accessing screw 1 7 Crankshaft end screw 1 8 Camshaft sprocket cover 1 9 Dowel pin 2 10 Cam...

Page 227: ...1 5 Fuel outlet hose 1 Disconnect 6 Cylinder head cover bolt 8 l 40 mm 1 57 in 7 Cylinder head cover bolt 20 l 60 mm 2 36 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder hea...

Page 228: ...ing 6 Pull rod 2 1 l 288 5 mm 11 358 in sky blue painting 7 Rocker arm shaft 4 8 Rocker arm 1 2 9 Rocker arm 2 2 10 Locknut 4 11 Adjusting screw 4 12 Rear rocker arm base 1 13 Front rocker arm base 1...

Page 229: ...on page 5 45 1 Push rod cover 2 2 O ring 2 3 O ring 2 4 Seal 2 5 Rear valve lifter case 1 6 Front valve lifter case 1 7 Valve lifter 4 For installation reverse the removal proce dure 1 7 3 5 6 2 1 4 3...

Page 230: ...shaft gear 1 9 Straight key 1 10 Right balancer driven gear 1 11 Straight key 1 12 Camshaft drive gear 1 13 Right balancer drive gear 1 14 Straight key 1 15 Oil delivery pipe 1 1 16 Camshaft cover 1 1...

Page 231: ...e the removal proce dure Removing the camshafts and right balancer Order Job Parts to remove Q ty Remarks New R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib R 60 Nm 6...

Page 232: ...o remove Q ty Remarks 1 Circlip 2 2 Washer 2 3 Decompression cam spring 2 4 Decompression cam 2 5 Decompression pin 2 6 Front cylinder camshaft 1 7 Rear cylinder camshaft 1 For assembly reverse the di...

Page 233: ...hen piston 1 is at TDC on the compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion a...

Page 234: ...osen Camshaft drive gear bolt 1 Right balancer driven gear bolt 2 NOTE Place a folded copper washer 3 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock...

Page 235: ...the camshaft Camshaft lobe dimensions Intake A 42 532 42 632 mm 1 6745 1 6784 in Limit 42 432 mm 1 6705 in Intake B 35 950 36 050 mm 1 4154 1 4193 in Limit 35 850 mm 1 4114 in Exhaust A 42 530 42 630...

Page 236: ...eck Camshaft drive gears Camshaft driven gears Front cylinder camshaft gears Rear cylinder camshaft gears Chips pitting roughness wear Replace the defective part s EAS23890 CHECKING THE ROCKER ARMS AN...

Page 237: ...Push rod Push rod end Bends damage Replace 2 Measure Push rod runout Out of specification Replace EAS23920 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check Valve lifter Blue discoloration ex...

Page 238: ...1 projects from the camshaft Check that the decompression cam 2 and de compression pin 1 moves smoothly 2 Check Decompression cam Decompression pin Damage wear Replace ET1D71031 CHECKING THE DECOMPRES...

Page 239: ...cover bolts in stages and in a crisscross pattern 3 Install Straight keys Right balancer drive gear 1 Right balancer driven gear 2 Camshaft driven gear NOTE Cover the crankcase hole with a clean rag...

Page 240: ...ring washer 4 Washer 5 Circlip 6 NOTE Align the projection a on the washer 3 with the punch mark b on the front cylinder cam shaft gear Install the conical spring washer 4 as shown in the illustration...

Page 241: ...mshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gears After tightening the camshaft driven gear bolt remove the copper washer to clean the te...

Page 242: ...h the camshaft drive gear as shown Example For bleeding the cylinder 2 intake valve lift er align mark 2 as shown i Leave the camshaft drive and driven gears aligned for five minutes to allow the valv...

Page 243: ...ods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right side of the vehicle The lengths of push rod 1 and push rod 2 are different Therefore be sure to instal...

Page 244: ...ree bolts 3 cannot be installed when the cover is in place Set the bolts in the cylinder head cover and then install the cover from the right side of the vehicle Bolts 4 l 40 mm 1 57 in Bolts 5 l 60 m...

Page 245: ...3 Engine temperature sensor 1 4 Oil pipe 1 1 5 Copper washer 4 6 Copper washer 2 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 11 Rear exhaust pipe joint cove...

Page 246: ...emarks 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 R 18 Nm 1 8 m kg 13 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 53 Nm 5 3 m kg...

Page 247: ...lve seats 2 Check Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylind...

Page 248: ...lts evenly and then torque them to specification 5 Install Engine bracket right upper side Engine bracket bolts right upper side Engine mounting bolts right upper side Engine bracket left upper side E...

Page 249: ...g bolt right up per side 59 Nm 5 9 m kg 43 ft lb Engine mounting bolt left upper side 66 Nm 6 6 m kg 48 ft lb LOCTITE Engine bracket bolt right upper side 53 Nm 5 3 m kg 38 ft lb Engine bracket bolt l...

Page 250: ...dure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 33 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Low...

Page 251: ...NOTE There should be no leakage at the valve seat 1 2 Remove Valve cotters NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor set 1 3 Remove Upper spring s...

Page 252: ...er valve stem to valve guide clearance NOTE 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 t...

Page 253: ...ng wear Replace the cylinder head 3 Measure Valve seat width C 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...

Page 254: ...results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping proce...

Page 255: ...stem seal 2 with the recommended lubricant 3 Install Valve guide 1 Free length intake 46 71 mm 1 84 in Limit 44 71 mm 1 76 in Free length exhaust 46 71 mm 1 84 in Limit 44 71 mm 1 76 in Installed comp...

Page 256: ...springs with the larger pitch a facing up 4 Install Valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 5 To secure the valve cotters o...

Page 257: ...marks Cylinder heads Refer to CYLINDER HEADS on page 5 33 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Circlip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil...

Page 258: ...a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cy...

Page 259: ...lace the piston and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into th...

Page 260: ...arance Out of specification Replace the piston pin and piston as a set EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top...

Page 261: ...from falling into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder numbering...

Page 262: ...nly Fuel tank Sub fuel tank Refer to FUEL TANK on page 6 1 Left rider footrest assembly Shift rod Sidestand Refer to ENGINE REMOVAL on page 5 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on...

Page 263: ...in 2 For installation reverse the removal proce dure Removing the clutch cover Order Job Parts to remove Q ty Remarks T R 12 Nm 1 2 m kg 8 7 ft Ib 5 3 4 5 2 1 R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m...

Page 264: ...y Remarks 1 Oil seal 1 2 Bearing 1 3 Clutch cover damper plate 1 4 Clutch cover damper 1 5 Crankshaft position sensor lead holder 3 6 Crankshaft position sensor 1 For installation reverse the removal...

Page 265: ...plate 9 8 Friction plate 2 9 9 Clutch boss nut 1 10 Conical spring washer 1 11 Washer 1 12 Wire circlip 1 13 Clutch plate 1 14 Friction plate 3 1 Inside diameter 135 mm 5 31 in 15 Clutch damper spring...

Page 266: ...Crankshaft position sensor rotor 1 31 Primary drive gear 1 32 Straight key 1 33 Washer 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E E...

Page 267: ...gear shaft 1 6 Left balancer drive gear 1 7 Straight key 1 8 Left balancer driven gear 1 9 Left balancer weight 1 1 10 Left balancer weight 2 1 11 Left balancer driven gear housing 1 12 Gasket 1 For i...

Page 268: ...eservoir diaphragm holder 1 4 Clutch master cylinder reservoir diaphragm 1 5 Clutch lever 1 6 Clutch master cylinder push rod pin 1 7 Clutch switch coupler 1 Disconnect 8 Clutch switch 1 9 Clutch hose...

Page 269: ...der Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse...

Page 270: ...5 Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For in...

Page 271: ...e Q ty Remarks 1 Boots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 6 Clutch release cylinder body 1 For assembly rev...

Page 272: ...nless there is serious clutch chattering EAS25090 REMOVING THE PRIMARY DRIVE GEAR 1 Loosen Primary drive gear bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primar...

Page 273: ...k Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS25130 CHEC...

Page 274: ...AS25190 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out o...

Page 275: ...balancer driven gear 3 NOTE Make sure that the punch marks a on the left balancer driven gear are facing toward left bal ancer weight 2 2 Remove Generator rotor Refer to REMOVING THE GENERATOR on pag...

Page 276: ...ghten the left balancer drive gear bolt EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Washer Straight key Primary drive gear Crankshaft position sensor rotor 1 Spacer Primary drive gear bolt 2...

Page 277: ...l spring washer mating surfaces with engine oil Install the conical spring washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch...

Page 278: ...1 Remove Clutch hose union bolt 1 Copper washers 2 Clutch hose 3 NOTE To collect any remaining clutch fluid place a container under the master cylinder and the end of the clutch hose ET1D71037 CHECKI...

Page 279: ...ghten the union bolt Turn the handlebar to the left and right to make sure the clutch hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Clutch master cylinder r...

Page 280: ...carefully EAS25330 CHECKING THE CLUTCH RELEASE CYLINDER 1 Install Clutch release cylinder body Cracks damage Replace the clutch re lease cylinder 2 Check Clutch release cylinder 1 Clutch release cyli...

Page 281: ...armful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clut...

Page 282: ...ousing Refer to CLUTCH on page 5 50 1 Washer 3 2 Circlip 2 3 Shift shaft 1 4 Shift shaft spring 1 5 Stopper lever 1 6 Collar 1 7 Stopper lever spring 1 8 Shift shaft spring stopper 1 For installation...

Page 283: ...r Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Collar Stopper lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the...

Page 284: ...on page 4 80 Clutch pipe Refer to CLUTCH on page 5 50 1 Stator coil coupler 1 Disconnect 2 Oil delivery pipe 2 1 3 Generator cover 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder...

Page 285: ...lutch idle gear shaft 1 3 Starter clutch idle gear 1 4 Generator rotor 1 5 Starter clutch 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Bearing 1 9 Bearing housing 1 For installation reverse the remova...

Page 286: ...r Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Insta...

Page 287: ...he generator shaft and the generator rotor hub When installing the rotor make sure the woo druff key is properly seated in the key way of the generator shaft Lubricate the generator rotor bolt threads...

Page 288: ...GENERATOR AND STARTER CLUTCH 5 76 Yamaha bond No 1215 90890 85505 Three Bond No 1215...

Page 289: ...AS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure 2 1 T R 1...

Page 290: ...ring 1 3 Oil seal 1 4 Circlip 1 5 Starter motor rear cover 1 6 Brush 2 7 Brush holder along with the brushes 1 8 Brush seat along with the brushes 1 9 Bearing 1 10 Gasket 2 11 Armature assembly 1 12 S...

Page 291: ...commutator 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 sta...

Page 292: ...e part s EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 NOTE Align the projection a on the brush holder with the slot b in the starter motor yoke 2 Install Starter motor front co...

Page 293: ...ase cylinder Refer to CLUTCH on page 5 50 Drive pulley Refer to BELT DRIVE on page 4 80 1 Oil pipe 2 1 2 Oil pipe 4 1 3 Transfer gear case cover 1 4 Transfer gear case gasket 1 5 Dowel pin 2 6 Transfe...

Page 294: ...le driven shaft Order Job Parts to remove Q ty Remarks 8 6 7 1 2 3 12 10 5 5 4 9 7 5 13 New New 7 E New New New New New New 11 LS LS R 10 Nm 1 0 m kg 7 2 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib R 18 Nm 1 8 m kg...

Page 295: ...marks 1 Transfer gear oil pump cover 1 2 Transfer gear oil pump outer rotor 1 3 Transfer gear oil pump inner rotor 1 4 Pin 1 5 Washer 1 6 Transfer gear oil pump shaft 1 7 Transfer gear oil pump housin...

Page 296: ...NK on page 6 1 1 Oil tank breather hose 1 Disconnect 2 Speed sensor 1 3 Oil tank damper 1 4 Dipstick 1 5 Dipstick joint 1 6 Drive pulley case 1 7 Dowel pin 2 8 Spacer 1 9 Transfer gear case 1 10 Dowel...

Page 297: ...ank cover 1 3 Oil tank cover gasket 1 4 Dowel pin 2 5 Oil strainer 1 6 Oil pipe 5 1 7 Oil tank 1 For assembly reverse the disassembly pro cedure 3 2 15 4 5 6 1 7 New R 10 Nm 1 0 m kg 7 2 ft Ib T R 28...

Page 298: ...age wear Replace the middle drive gear middle driven shaft and primary chain as a set 2 Check Primary chain Damage stiffness Replace the primary chain middle drive gear and middle driven shaft as a se...

Page 299: ...p shaft with the groove in the inner ro tor 3 Check Transfer gear oil pump operation Refer to CHECKING THE TRANSFER GEAR OIL PUMP on page 5 86 EAS25530 INSTALLING THE TRANSFER GEAR CASE 1 Install Spac...

Page 300: ...Temporarily install the drive pulley nut onto the middle driven shaft 3 Install Conical spring washer 1 Middle drive gear nut 2 NOTE Lubricate the middle drive gear nut threads and conical spring was...

Page 301: ...R CLUTCH on page 5 72 1 Neutral switch 1 2 Oil pipe 3 1 3 Oil strainer 2 4 Oil delivery pipe 3 1 5 Engine oil pump driven gear stopper 1 6 Engine oil pump driven gear 1 7 Oil baffle plate left crankca...

Page 302: ...rts to remove Q ty Remarks New 1 11 9 4 5 6 2 5 7 3 13 8 9 10 12 T R 10 Nm 1 0 m kg 7 2 ft Ib 24 Nm 2 4 m kg 17 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R...

Page 303: ...AFT on page 5 101 Transmission Refer to TRANSMISSION on page 5 107 1 Oil baffle plate right crankcase 1 2 Bearing retainer 2 3 Bearing retainer 2 4 Oil seal 2 5 Bearing 4 For installation reverse the...

Page 304: ...ure the crankcase halves sepa rate evenly EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfa...

Page 305: ...1 Oil pipe R mark 2 Dowel pins 3 Joint pipe 4 3 Install Left crankcase onto the right crankcase NOTE Tap lightly on the left crankcase with a soft face hammer 4 Install Crankcase bolts M6 Crankcase bo...

Page 306: ...oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair A Right crankcase B Left crankcase 4 1 5 3 6 7 2 8 A 21 20 16 15 14 19...

Page 307: ...OIL PUMP Removing the oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Oil pump assembly 1 For installation reverse the removal proce dure 1 T R 24...

Page 308: ...1 6 Oil strainer 1 7 Pin 2 8 Ball spring 1 9 Oil scavenging pump outer rotor 2 1 10 Oil scavenging pump inner rotor 2 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Relief valve spring 1 14 Relief valve...

Page 309: ...all guide 1 24 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks E E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg...

Page 310: ...lve spring Damage wear Replace the defective part s ET1D71035 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 1 Measure Ball spring free length Relief valve spring free length Out of specification Re...

Page 311: ...cavenging pump inner rotor 2 15 Oil scavenging pump outer rotor 2 16 Ball spring 17 Pins 18 Oil strainer 19 Oil pump housing 1 20 Pin 21 Oil scavenging pump inner rotor 1 22 Oil scavenging pump outer...

Page 312: ...98 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump assembly bolt 24 Nm 2 4 m kg 17 ft lb E...

Page 313: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end...

Page 314: ...e the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin t...

Page 315: ...re f Tighten the connecting rod bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specifi...

Page 316: ...5 Measure Crankshaft journal diameter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside dia...

Page 317: ...gn the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection...

Page 318: ...ntil it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Generator shaft 1 Crankshaft assembly 2 CAUTION ECA13970 To avoid scratching the crankshaft and to ease the inst...

Page 319: ...Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork 1 2 4 Shift fork 2 1 5 Drive axle assembly 1 6 Main a...

Page 320: ...d pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Collar 1 6 Toothed washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Toothed washer 1 11 4th pinion...

Page 321: ...y Remarks 1 Circlip 1 2 Washer 1 3 1st wheel gear 1 4 Collar 1 5 4th wheel gear 1 6 Circlip 1 7 Toothed washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer...

Page 322: ...TRANSMISSION 5 110 17 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks...

Page 323: ...lace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Da...

Page 324: ...e the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles alig...

Page 325: ...hift forks should face towards the left side of the engine 2 Check Transmission Rough movement Repair NOTE Apply engine oil to each gear and bearing thor oughly Before assembling the crankcase make su...

Page 326: ...ROTTLE BODIES 6 6 REMOVING THE FUEL HOSE 6 11 CHECKING THE INJECTORS 6 11 CHECKING THE THROTTLE BODIES 6 11 CHECKING THE ROLLOVER VALVES 6 11 CHECKING THE PRESSURE REGULATOR 6 11 CHECKING THE PRESSURE...

Page 327: ...sender coupler 1 Disconnect 4 Fuel tank breather hose 1 Disconnect 5 Air vent hose fuel pump to fuel hose joint 1 Disconnect 6 Fuel tank 1 7 Fuel tank bracket rear side 1 8 Fuel tank bracket front sid...

Page 328: ...mp coupler 1 Disconnect 2 Fuel hose connector cover 1 3 Fuel outlet hose 1 Disconnect 4 Air vent hose fuel pump to fuel hose joint 1 5 Fuel return hose fuel return pipe to sub fuel tank 1 Disconnect 6...

Page 329: ...nt in the areas shown in the illustration c Turn the screws 1 clockwise NOTE Turn the screws until they stop d Disconnect the fuel hose fuel hose joint to fuel pump 1 and air vent hose fuel pump to fu...

Page 330: ...NG THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the sub fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in...

Page 331: ...the clips a e Install the fuel hose joint caps NOTE Install the fuel hose joint caps completely onto the fuel hose joints 2 Install Meter assembly couplers Fuel sender coupler NOTE Make sure that the...

Page 332: ...only 3 Fuel tank breather hose 1 4 Canister purge hose 1 For California only 5 Rollover valve 1 1 6 Rollover valve 2 1 7 Rollover valve hose 4 8 Fuel tank breather overflow hose 1 9 Canister 1 For Ca...

Page 333: ...to pres sure regulator 1 3 Air filter case breather hose 1 1 4 Air filter case breather hose 2 1 5 Hose clamp 1 6 Pressure regulator 1 7 Fuel return hose 1 8 Fuel return pipe 1 9 Pressure regulator b...

Page 334: ...n page 5 1 1 Throttle position sensor coupler 1 Disconnect 2 Cylinder 1 intake air pressure sensor hose 1 3 Cylinder 2 intake air pressure sensor hose 1 4 Canister purge hose 1 For California only 5 T...

Page 335: ...et hose 1 Disconnect 4 Fuel hose intake manifold assembly to pres sure regulator 1 5 Cylinder 2 ISC idle speed control unit outlet hose 1 Disconnect 6 Cylinder 1 ISC idle speed control unit outlet hos...

Page 336: ...1 Disconnect 2 Cylinder 2 injector coupler 1 Disconnect 3 Sub wire harness 2 1 4 Fuel pipe 1 5 Injector joint 1 1 6 Injector joint 2 1 7 Injector 2 For assembly reverse the disassembly pro cedure 5 7...

Page 337: ...ies as a set 2 Check Fuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with co...

Page 338: ...Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten...

Page 339: ...make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel...

Page 340: ...2 ISC idle speed control unit outlet hose 2 4 Cylinder 1 ISC idle speed control unit outlet hose 2 5 ISC idle speed control unit inlet hose 1 6 Cylinder 2 left ignition coil 1 7 Cylinder 2 right ignit...

Page 341: ...ISC IDLE SPEED CONTROL UNIT 6 15 ET1D71010 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 1 Check Hoses Loose connections Connect properly Cracks damage Replace...

Page 342: ...RGING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING 7 15 LIGHTING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 19 SIGNALING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 23 FUEL INJECTIO...

Page 343: ...TION SENSOR 7 84 CHECKING THE LEAN ANGLE SENSOR 7 84 CHECKING THE STARTER MOTOR OPERATION 7 85 CHECKING THE STATOR COIL 7 85 CHECKING THE RECTIFIER REGULATOR 7 85 CHECKING THE HORNS 7 86 CHECKING THE...

Page 344: ......

Page 345: ...G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G B L R G R B R B R B R B R B R B C C D Y B Gy W W R B G B R W R BLACK L W R B G R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy...

Page 346: ...estand switch 19 Crankshaft position sensor 23 Lean angle sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 C...

Page 347: ...lugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand swit...

Page 348: ...to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace t...

Page 349: ...to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the sidestand switch 12 Check the relay unit diode R...

Page 350: ...IGNITION SYSTEM 7 6...

Page 351: ...W G Br L R G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G B L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R B G R L L B G B R B L W G GRAY W Gy DARK GRAY Gy G...

Page 352: ...tery 8 Starter relay 9 Starter motor 10 Diode 1 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Diode 2 16 Sidestand switch 27 ECU electronic control unit 54 Clutch switch 68 Engi...

Page 353: ...lled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating wh...

Page 354: ...ED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Diode 2 7 Relay unit starting circuit cut off relay 8 Relay unit diode 9 Clutch switch 10 Sidestand switc...

Page 355: ...Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 85 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the...

Page 356: ...itch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the sidestand...

Page 357: ...L E Y BLACK L B B L Gy Gy B Gy B L B L L P Y B L L P W P W BLACK B L L P Y BLACK B L L W L B L W Y B L L B L W Y B L Br W BLACK Br B Br Br Br B B B B B Br W B L B G W R L B R L G W B B B L Y G L Br B...

Page 358: ...CHARGING SYSTEM 7 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 6 Battery...

Page 359: ...he battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 85 Re...

Page 360: ...CHARGING SYSTEM 7 16...

Page 361: ...G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G B L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R B G R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy G...

Page 362: ...52 Headlight relay 55 Dimmer switch 59 Front right turn signal position light 60 Front left turn signal position light 64 Headlight high beam 65 Headlight low beam 70 Accessory light switch 71 Accesso...

Page 363: ...fuses Main headlight signaling system taillight and ECU Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean...

Page 364: ...LIGHTING SYSTEM 7 20 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 17 Properly connect or repair the lighting sys tem wiring The lighting system circuit is OK...

Page 365: ...L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G...

Page 366: ...rning light 45 Left turn signal indicator light 46 Right turn signal indicator light 48 Fuel sender fuel tank 49 Horn 1 50 Horn 2 51 Turn signal relay 56 Turn signal switch 57 Horn switch 59 Front rig...

Page 367: ...ignition signaling system and ECU Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals...

Page 368: ...the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CI...

Page 369: ...lay unit diode Refer to CHECKING THE DI ODES on page 7 81 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signali...

Page 370: ...the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED...

Page 371: ...R G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G Br L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R G B R B L L B G B R B L W G GRAY W G DARK GRAY Gy G G Gy G B...

Page 372: ...sor 25 Air temperature sensor 26 Engine temperature sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinde...

Page 373: ...ode has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one...

Page 374: ...system Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached hose Able Able 15 Throttle position sen sor open or short circuit Throttle position sensor open or short circu...

Page 375: ...coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 37 ISC valve stuck fully open Engine speed is high when the en gine is idling Able Able 41 Lea...

Page 376: ...en left idling The ECU automatically stops the en gine after 20 minutes if it is left idling Able Able Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc...

Page 377: ...ess the switch for 8 seconds or more NOTE All displays on the meter disappear except the clock and odometer trip meter fuel reserve trip meter clock displays dIAG appears on the odometer trip meter fu...

Page 378: ...properly installed sensor 13 Cylinder 1 intake air pres sure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 1 intake air pressure sensor Malfunction in...

Page 379: ...ort circuit detected Open or short circuit in wire sub lead Open or short circuit in wire harness Defective engine temperature sensor Malfunction in ECU Improperly installed sensor 11 30 The vehicle h...

Page 380: ...detected in the neutral switch Open circuit in wire harness Defective speed sensor Malfunction in vehicle speed sensor detect ed Defective neutral switch Malfunction in the engine side of the neutral...

Page 381: ...der 1 intake air pres sure Displays the cylinder 1 in take air pressure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK 04 Pressure dif...

Page 382: ...r Displays the operating angle Engine trouble warning light comes on twice once when the EXUP valve is closing and once when it is opening 60 EEPROM fault code dis play No history 00 History exists 01...

Page 383: ...times Connect an ignition checker 33 Cylinder 2 left or right ig nition coil Actuates the cylinder 2 left or right ignition coil five times at one second intervals Illuminates the engine trou ble warn...

Page 384: ...ction table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 7 33 52 Headlight relay Actuates the headlight relay for five cyc...

Page 385: ...Crankshaft position sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it an...

Page 386: ...er for any pins that may be 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 ci...

Page 387: ...ing the en gine and oper ating it at idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tio...

Page 388: ...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 and or sub lead Repair or replace if...

Page 389: ...Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 7 90 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable ca...

Page 390: ...lace if defective Refer to CHECKING THE SWITCHES on page 7 71 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item com...

Page 391: ...ensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler...

Page 392: ...oupler for any pins that may be 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 shor...

Page 393: ...ing the en gine and oper ating it at idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tio...

Page 394: ...er brown brown black black 4 Defective engine temperature sensor Execute the diagnostic mode Code No 11 Replace if defective Refer to CHECKING THE EN GINE TEMPERATURE SEN SOR on page 7 87 Fault code N...

Page 395: ...pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idl...

Page 396: ...any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at...

Page 397: ...pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idl...

Page 398: ...any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at...

Page 399: ...Y on page 3 8 3 ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is de tected with the ISC valve stuck fully open even though signals for the valve to...

Page 400: ...any pins that may be 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...

Page 401: ...dition of the coupler If 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 A...

Page 402: ...d relay unit coupler fuel pump relay sky blue sky blue Between relay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black B 3 Faulty shift dru...

Page 403: ...ed blue red blue Between relay unit coupler fuel pump relay and battery termi nal red red Between relay unit coupler fuel pump relay and diode 2 cou pler red white red white Between diode 2 coupler an...

Page 404: ...7 76 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 7 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Bet...

Page 405: ...ue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnos...

Page 406: ...ue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnosti...

Page 407: ...L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W G DARK GRAY Gy G G Gy G B Gy G...

Page 408: ...TEM 7 64 3 Main switch 4 Main fuse 6 Battery 7 Fuel injection system fuse 11 Relay unit 13 Fuel pump relay 15 Diode 2 17 Fuel pump 27 ECU electronic control unit 68 Engine stop switch 77 Ignition fuse...

Page 409: ...CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the main switch 4...

Page 410: ...FUEL PUMP SYSTEM 7 66 NG OK 8 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 7 63 Properly connect or repair the fuel pump system wiring Replace the ECU...

Page 411: ...ELECTRICAL COMPONENTS 7 67 EAS27970 ELECTRICAL COMPONENTS 11 3 6 7 8 10 4 9 12 13 5 2 1 14...

Page 412: ...ignition coil 3 Fuel sender 4 Engine temperature sensor 5 Cylinder 1 left ignition coil 6 Cylinder 1 right ignition coil 7 ECU electronic control unit 8 EXUP servo motor 9 Speed sensor 10 Rectifier r...

Page 413: ...ELECTRICAL COMPONENTS 7 69 16 18 2 11 13 9 8 10 12 14 15 17 1 3 4 5 6 7...

Page 414: ...Throttle position sensor 5 Cylinder 1 intake air pressure sensor 6 Fuse box 7 Starter relay 8 Fuel injection system fuse 9 Battery 10 Diode 2 11 Turn signal relay 12 Headlight relay 13 Relay unit 14...

Page 415: ...3 10 6 12 9 Y G L G B P Br Y R W B R L W W B R Br R Br L Y L B ON OFF G Y G B PUSH Ch Br W Dg B Y R L R GRAY Dg Ch GRAY B B G YG B BLUE Y G G L GRAY B P Y R Br W L Y B Y B B BLACK B B BLACK 8 7 BLUE B...

Page 416: ...h 2 Engine stop switch 3 Start switch 4 Accessory light switch 5 Front brake light switch 6 Neutral switch 7 Sidestand switch 8 Rear brake light switch 9 Clutch switch 10 Horn switch 11 Dimmer switch...

Page 417: ...er to 0 and to the 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 e...

Page 418: ...ition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW1D71009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them unt...

Page 419: ...page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse...

Page 420: ...TERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC1D71020 This is a sealed battery Never remove the...

Page 421: ...e it from the vehicle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in t...

Page 422: ...charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amper...

Page 423: ...tinuity with the pocket tester If the continuity reading is incorrect re place the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester 1 and battery 12 V to the relay termin...

Page 424: ...t tester DC 20 V to the turn signal relay terminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1...

Page 425: ...ontinuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky...

Page 426: ...Check the diode 2 for continuity d Check the diode 2 for no continuity ET1D71012 CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshoo...

Page 427: ...ug cap as shown c Measure the spark plug cap resistance EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni tion coils 1 Check Primary coil resistance Out of specif...

Page 428: ...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...

Page 429: ...arks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the rectifier regulato...

Page 430: ...from the horn terminals b Connect the pocket tester 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn...

Page 431: ...sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the engine temperature sensor re sistance 3 In...

Page 432: ...warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes e...

Page 433: ...ne is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke...

Page 434: ...ke air pressure sensors 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown b Turn th...

Page 435: ...ocket tester 100 to the air temperature sensor terminals as shown b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do...

Page 436: ...NGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANC...

Page 437: ...riorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged...

Page 438: ...gn 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...

Page 439: ...ct oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Dam...

Page 440: ...ight LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn si...

Page 441: ...FF D D C C D D C D D E E E B B B B B B L N R PUSH A A BLACK A A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32 32 32 33 34 35 36 37 38 39 40 41 42 43 44 45...

Page 442: ...n 2 51 Turn signal relay 52 Headlight relay 53 Left handlebar switch 54 Clutch switch 55 Dimmer switch 56 Turn signal switch 57 Horn switch 58 Select switch 59 Front right turn signal position light 6...

Page 443: ......

Page 444: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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