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ELECTRICAL COMPONENTS

7-54

1. Engine temperature sensor
2. Intake air pressure sensor
3. ISC (idle speed control) valve
4. Fuel injector
5. Throttle position sensor
6. ECU (engine control unit)
7. Headlight relay (on/off)
8. Fuel pump relay
9. Turn signal/hazard relay
10.Lean angle sensor
11.Fuel pump
12.Intake air temperature sensor
13.Stator coil assembly
14.Air induction system solenoid
15.O

2

sensor

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Summary of Contents for SR400 2014

Page 1: ...2014 SERVICE MANUAL SR400 SR400E 2RD 28197 E0 ...

Page 2: ......

Page 3: ...0 SR400E SERVICE MANUAL 2013 by Yamaha Motor Co Ltd First edition November 2013 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

Page 5: ...on title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order...

Page 6: ... with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data YAMAHA GREASE F Engine oil Apply locking agent LOCTITE Silicone fluid Replace the part with a new one G M BF B T R LS M S F E LT S New ...

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

Page 8: ......

Page 9: ...2 FI SYSTEM 1 3 FUEL LINE CHART 1 4 IMPORTANT INFORMATION 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 5 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 5 CIRCLIPS 1 6 RUBBER PARTS 1 6 BASIC SERVICE INFORMATION 1 7 QUICK FASTENERS 1 7 ELECTRICAL SYSTEM 1 7 SPECIAL TOOLS 1 12 ...

Page 10: ...LE 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 This information will be needed to order spare parts 1 1 ...

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

Page 12: ... input from the throttle position sensor ISC idle speed control valve engine temperature sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel th...

Page 13: ...FEATURES 1 4 EAS2RD1002 FUEL LINE CHART 1 A B 2 5 6 3 4 1 Fuel tank 2 Fuel cock 3 Fuel pump case 4 Fuel pump 5 Fuel injector 6 Pressure regulator A Feeding side B Return side ...

Page 14: ...p all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil sea...

Page 15: ...ng surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS32080 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are s...

Page 16: ...sh the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastener insert the fastener into the part to be secured and tighten the screw a EAS30401 ELECTRICAL SYSTEM Electrical parts ha...

Page 17: ... could damage the electrical components NOTICE ECA16770 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead If a tool or similar item contacts the vehicle while only the negative battery lead is con nected a spark could be generated which is extremely dangerous NOTICE ECA16610 Turn the main switch to OFF before dis con...

Page 18: ... loosen or damage the leads NOTICE ECA16640 For waterproof couplers never insert the tester probes directly into the coupler When performing any checks using a waterproof coupler use the specified test harness or a suitable commercially available test har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE EC...

Page 19: ...al times 3 Connect Lead Coupler Connector TIP When connecting a coupler or connector push both sections of the coupler or connector to gether until they are connected securely Make sure all connections are tight 4 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer ...

Page 20: ...ed at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 k at 0 C 32 F 290 390 at 80 C 176 F ...

Page 21: ...er to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 14 5 15 Weight 90890 01084 Weight YU 01083 3 5 14 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5...

Page 22: ...68 Spanner wrench YU 01268 4 46 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 54 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 54 Adapter M12 90890 01278 Adapter 3 YU 90063 5 54 Spacer 90890 01288 5 54 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 23: ...9 4 41 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 41 4 42 Fork seal driver attachment ø35 90890 01369 Replacement 35 mm YM A9409 5 4 41 Steering nut wrench 90890 01385 3 19 Spoke nipple wrench 8 9 90890 01522 Spoke nipple wrench 8 9 YM 01522 3 15 Tool name Tool No Illustration Reference pages YU 01304 YM A9409 7 YM A5142 4 ...

Page 24: ... 7 70 7 71 7 72 Pressure gauge 90890 03153 Pressure gauge YU 03153 6 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 71 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 6 FI diagnostic tool 90890 03182 FI diagnostic tool YU 03182 3 7 6 13 7 25 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 6 12 Tool name Tool No Illustration Reference...

Page 25: ...or 3P YU 03213 7 67 Valve guide remover installer set ø8 0 90890 04014 Valve guide remover 8 0 mm YM 01200 Valve guide reamer 8 0 mm YM 01211 5 18 Extension 90890 04082 5 1 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 31 5 33 Tappet adjusting tool 4 mm 90890 04133 Six piece tappet set YM A5970 3 6 Tool name Tool No Illustration Reference pages ø9 ø8 ø10 ø3 ø4 YM A5970 ...

Page 26: ...ecker YM 34487 7 66 Digital tachometer 90890 06760 Digital tachometer YU 39951 B 3 7 Vacuum pressure pump gauge set 90890 06945 Pressure vacuum tester YB 35956 B 6 12 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 11 5 50 Tool name Tool No Illustration Reference pages ...

Page 27: ...TIONS 2 10 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 21 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 CABLE ROUTING 2 33 ...

Page 28: ...US Dimensions Overall length 2085 mm 82 1 in Overall width 750 mm 29 5 in Overall height 1095 mm 43 1 in Seat height 785 mm 30 9 in Wheelbase 1410 mm 55 5 in Ground clearance 130 mm 5 12 in Minimum turning radius 2400 mm 94 5 in Weight Curb weight 174 kg 384 lb Maximum load 150 kg 331 lb ...

Page 29: ... engine oil grade API service SG type or higher JASO standard MA Lubrication system Dry sump Engine oil quantity Quantity disassembled 2 40 L 2 54 US qt 2 11 Imp qt Without oil filter element replacement 2 00 L 2 11 US qt 1 76 Imp qt With oil filter element replacement 2 10 L 2 22 US qt 1 85 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clea...

Page 30: ...12 mm 0 0028 0 0047 in Exhaust 0 12 0 17 mm 0 0047 0 0067 in Valve dimensions Valve head diameter intake 47 00 47 20 mm 1 8504 1 8583 in Valve head diameter exhaust 39 00 39 20 mm 1 5354 1 5433 in Valve seat contact width intake 1 30 mm 0 0512 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 1 30 mm 0 0512 in Limit 1 6 mm 0 06 in Valve stem diameter intake 7 975 7 990 mm 0 3140 0 3146 in L...

Page 31: ... 63 kgf mm 259 23 lbf in Spring rate K1 exhaust 35 30 N mm 3 60 kgf mm 201 56 lbf in Spring rate K2 exhaust 45 40 N mm 4 63 kgf mm 259 23 lbf in Installed compression spring force intake 160 83 N 16 40 kgf 36 15 lbf Installed compression spring force exhaust 160 83 N 16 40 kgf 36 15 lbf Spring tilt intake 1 9 mm 0 07 in Spring tilt exhaust 1 9 mm 0 07 in Winding direction intake Clockwise Winding ...

Page 32: ... pcs Clutch plate thickness 1 10 1 30 mm 0 043 0 051 in Plate quantity 7 pcs Warpage limit 0 05 mm 0 002 in Clutch spring free length 34 90 mm 1 37 in Limit 33 16 mm 1 31 in Spring quantity 6 pcs Push rod bending limit 0 20 mm 0 008 in Transmission Transmission type Constant mesh 5 speed Primary reduction ratio 2 567 77 30 Secondary reduction ratio 2 947 56 19 Final drive Chain Operation Left foot...

Page 33: ...gine idling speed 1200 1400 r min Plug seat temperature 170 0 190 0 C 338 00 374 00 F CO AI system ON 3 00 Intake vacuum 26 0 32 0 kPa 195 240 mmHg 7 7 9 4 inHg Oil temperature 55 0 65 0 C 131 00 149 00 F Fuel line pressure at idling 310 360 kPa 3 1 3 6 kgf cm2 45 0 52 2 psi Regulated pressure 329 kPa 3 3 kgf cm2 47 7 psi Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Air induction system Solenoi...

Page 34: ...re Type With tube Size 90 100 18M C 54S Manufacturer model METZELER ME77 Front Wear limit front 1 5 mm 0 06 in AUS 1 6 mm 0 06 in EUR Rear tire Type With tube Size 110 90 18M C 61S Manufacturer model METZELER ME77 Wear limit rear 1 5 mm 0 06 in AUS 1 6 mm 0 06 in EUR Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 175 kPa 1 75 kgf cm2 25 psi Rear 200 kPa 2 00 kgf ...

Page 35: ...ering bearing type Angular bearing Center to lock angle left 42 0 Center to lock angle right 42 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 150 0 mm 5 91 in Fork spring free length 492 9 mm 19 41 in Limit 483 0 mm 19 02 in Fork spring installed length 487 9 mm 19 21 in Spring rate K1 4 50 N mm 0 46 kgf mm 25 70 lbf in Spring rate K2 6...

Page 36: ...tandard 1 Maximum 5 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 0 5 mm 0 02 in Drive chain Type manufacturer 428HVS DAIDO Number of links 130 Drive chain slack 30 0 40 0 mm 1 18 1 57 in 15 link length limit 191 5 mm 7 54 in ...

Page 37: ...A 5000 r min Stator coil resistance 0 184 0 276 W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 35 0 A Battery Model GT4B 5 Voltage capacity 12 V 2 5 Ah Specific gravity 1 350 Manufacturer GS YUASA Ten hour rate charging current 0 25 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 0 W 55 0 W ...

Page 38: ...istor 1350 1900 25 C 1350 1900 77 F Fuel injection sensor Crankshaft position sensor resistance 192 288 Intake air pressure sensor output voltage 1 20 4 20 V Intake air temperature sensor resistance 290 390 80 C 290 390 176 F Engine temperature sensor resistance 210 220 100 C 210 220 212 F Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Parking lighti...

Page 39: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0...

Page 40: ...hort M10 1 18 Nm 1 8 m kgf 13 ft lbf Height 39 8 42 3 mm 1 57 1 67 in Cylinder head cover nut M8 2 20 Nm 2 0 m kgf 14 ft lbf Cylinder head bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Spark plug M14 1 25 Nm 2 5 m kgf 18 ft lbf Cylinder nut M10 4 38 Nm 3 8 m kgf 27 ft lbf Cylinder stud bolt M10 4 18 Nm 1 8 m kgf 13 ft lbf Cylinder bolt M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Oil check bolt engine oil pres sure che...

Page 41: ... Oil pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil filter cover bleeder bolt M5 1 5 Nm 0 5 m kgf 3 6 ft lbf Oil pipe stay bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Oil hose 1 union nut oil tank side M14 1 35 Nm 3 5 m kgf 25 ft lbf Oil hose 2 union nut oil tank side M16 1 35 Nm 3 5 m kgf 25 ft lbf Throttle body joint bolt M2 2 10 Nm 1 0 m kgf 7 2 ft lbf Throttle body joint clamp screw engine side M5 1 3...

Page 42: ...gf 5 1 ft lbf Cover bolt right inner side of the crankcase M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Stator coil assembly lead holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Kick crank bolt M8 1 20 Nm 2 0 m kgf 14 ft lbf Ratchet wheel guide bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Primary drive gear nut M16 1 60 Nm 6 0 m kgf 43 ft lbf Clutch spring bolt M6 6 9 Nm 0 9 m kgf 6 5 ft lbf Clutch boss nut M18 1 60 Nm 6 0 ...

Page 43: ...it screw M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Tachometer cable M12 1 4 5 Nm 0 45 m kgf 3 3 ft lbf Rear shock absorber assembly lower nut M10 2 30 Nm 3 0 m kgf 22 ft lbf Tension bar nut swingarm side M8 1 19 Nm 1 9 m kgf 14 ft lbf Tension bar nut brake shoe plate side M8 1 19 Nm 1 9 m kgf 14 ft lbf Chain case bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Seat bolt M8 2 16 Nm 1 6 m kgf 12 ft lbf Mudguard bolt M6...

Page 44: ... 1 6 m kgf 12 ft lbf Rear turn signal light bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear turn signal light nut M12 2 7 Nm 0 7 m kgf 5 1 ft lbf Tail brake light assembly nut M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear reflector nut M5 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Fuel pump case mounting bolt front side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump case mounting bolt rear side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Fuel ...

Page 45: ...2 7 Nm 0 7 m kgf 5 1 ft lbf Brake lever bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake lever nut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake lever adjusting screw lock nut M6 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Lever holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Decompression lever nut M5 1 2 3 Nm 0 23 m kgf 1 7 ft lbf Headlight assembly nut M8 2 8 Nm 0 8 m kgf 5 8 ft lbf Meter stay nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf...

Page 46: ... lbf Front footrest assembly nut M8 4 32 Nm 3 2 m kgf 23 ft lbf Rear footrest nut M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Rear footrest cover screw M5 4 3 8 Nm 0 38 m kgf 2 8 ft lbf Ignition coil bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator stay bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Throttle cable guide screw M5 1 3 8 Nm 0 38 m kgf 2 8 ft l...

Page 47: ...rcumference Piston outer circumference Piston ring Cylinder sleeve inner circumference Valve stem Valve stem end Valve stem seal Valve guide Rocker arm shaft outer circumference Camshaft lobe and journal Rocker arm inner circumference Decomp cam outer circumference Kick gear inner circumference Drive axle outer circumference Main axle outer circumference Ratchet wheel inner circumference Kick idle...

Page 48: ...ather Kick crank rotating part sliding part Lubrication point Lubricant Steering bearing and bearing races Throttle grip inner side and throttle cable end Clutch cable end Brake lever pivoting points and metal to metal moving parts Master cylinder piston end and brake lever adjusting screw end Clutch lever pivoting points and metal to metal moving parts Brake pedal shaft Centerstand pivoting point...

Page 49: ... Rear brake camshaft mating surfaces shaft Rear brake shoe plate pin pivot Rear wheel oil seal lip Rear wheel axle Rear wheel drive hub Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Caliper support bolt Lubrication point Lubricant LS LS LS LS BF BF S S ...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 1 2 3 4 5 7 8 6 9 10 ...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Rocker arm shaft 2 Crankshaft 3 Oil filter element 4 Check ball 5 Oil feed pump 6 Scavenging pump 7 Oil strainer 8 Drive axle 9 Main axle 10 Oil tank frame ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS 1 2 4 5 6 4 8 10 3 7 9 ...

Page 53: ...N SYSTEM CHART AND DIAGRAMS 2 26 1 Engine oil level gauge 2 Breather hose 3 Oil tank 4 Union bolt 5 Oil delivery pipe clamp 6 Oil delivery pipe 7 Oil pipe 8 Oil hose 1 9 Oil drain bolt oil tank side 10 Oil hose 2 ...

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

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil hose 2 2 Scavenging pump 3 Oil drain bolt crankcase side A To oil tank ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 1 2 3 4 5 8 10 9 a b b a 6 7 ...

Page 57: ...STEM CHART AND DIAGRAMS 2 30 1 Crankshaft 2 Oil filter element 3 Check ball 4 Oil feed pump 5 Oil strainer 6 Oil pipe 7 Oil delivery pipe 8 Rocker arm exhaust side 9 Camshaft 10 Rocker arm intake side A From oil tank ...

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

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Clutch push lever shaft 2 Main axle 3 Oil pump 4 Drive axle A To oil tank ...

Page 60: ...CABLE ROUTING 2 33 EAS20430 CABLE ROUTING Right side view ...

Page 61: ...e vehicle D Fasten the oil hose 2 and fuel sender lead with the clamp E Point the end of the clamp toward the outside of the vehicle F To the fuel tank G Route the throttle cable above the wire harness H Route the wire harness to the right side of the head pipe I Route the brake hose to the inside of the front fork J Fasten the brake hose with the clamp K Route the O2 sensor lead outside of the fu...

Page 62: ...CABLE ROUTING 2 35 Left side front view ...

Page 63: ...he throttle cables through the guide E Silicon solution or soap water may be applied when a boot is installed to the clutch cable F Fasten with the clamp at an area where no fuel tank breather hose protector is mounted G Pass the clutch cable through the engine mount guide H Route the wire harness to the inside of the spark plug lead I Route the wire harness and throttle cable above the tank stopp...

Page 64: ...CABLE ROUTING 2 37 Left side rear view ...

Page 65: ...ose fuel pump fuel rail I Fasten the sidestand switch lead and two stator coil assembly leads to the external side of the engine mount with the plastic locking tie Point the end forward and cut off an excess end J Fasten the sidestand switch lead two stator coil assembly leads and air filter case drain hose with the clamp K Avoid slack of the lead in this space L Fasten the sidestand switch lead a...

Page 66: ...CABLE ROUTING 2 39 Upper front view ...

Page 67: ...ad and front brake light switch lead with the plastic locking tie B Route the wire harness to the inside of the frame C Fasten the left handlebar switch lead and clutch switch lead with the plastic locking tie D Front of the vehicle E Fasten the leads to the lower side of the vehicle with the plastic locking tie Point the tie of the plas tic locking tie forward with its end facing down ward Do not...

Page 68: ...CABLE ROUTING 2 41 Upper rear view ...

Page 69: ... right turn signal light lead with the clamp Two locations E Fasten the tail brake light lead rear left turn signal light lead and rear right turn signal light lead with the plastic locking tie The plastic locking tie should be located just in front of the clamp and the end of the plastic locking tie should point toward the inside of the vehicle At this time avoid slack of the rear left turn signa...

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

Page 71: ... speedometer cable D Route the front right turn signal light lead inside of the headlight through the rear of the tachometer cable E Fasten the meter lead tachometer main switch lead front brake light switch lead right handlebar switch lead and clutch switch lead with the clamp F Over 20 mm 0 79 in away from the end G Point the open end of the clamp forward H Harness coming into the inside of the ...

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

Page 73: ...te the speedometer cable to the front of the lower bracket B Fasten the brake hose with the clamp C Route the tachometer cable to the upper right side of the lower bracket D Route the tachometer cable to the inside of the headlight beam adjusting stay E Route the throttle cable to the front of the brake hose and the rear of the tachometer cable ...

Page 74: ...CABLE ROUTING 2 47 Fuel tank breather hose ...

Page 75: ... cut off an excess end F Insert the fuel tank breather hose 2 into the base of the plug G Point the open end of the clamp to the right H Insert the fuel tank breather hose 2 into the base of the rollover valve I Insert the fuel tank breather hose 1 into the base of the rollover valve J Install the fuel tank breather hose 1 so that its white paint mark is located at the fuel tank side K Point the o...

Page 76: ...CABLE ROUTING 2 49 Fuel pump case ...

Page 77: ...be located below the grommet D Point the open end of the clamp to the inside E Point the end of the clamp downward F Detailed clamp installation G Install a clamp halfway between the hose end and the bulge of a pipe end H Point the end of the clamp to the left I Insert the pump case breather hose fuel pump case fuel tank into the end of the round portion at the fuel pump case J Insert the fuel hos...

Page 78: ...CABLE ROUTING 2 51 Throttle body upper view ...

Page 79: ...er C 20 0 mm 0 79 in D Point the green paint mark upward E Align the fuel hose and fuel pipe yellow paint marks with each other Point the paint mark upward F 60 G Point the end of the clamp to the inside H Point the end of the clamp to the fuel rail side I Insert the fuel hose pressure regulator fuel pipe into the bulge of the pressure regulator J To the air filter case K Point the end of the clam...

Page 80: ...CABLE ROUTING 2 53 Throttle body side view ...

Page 81: ...ank below the frame B Point the end of the clamp toward the outside of the vehicle C 10 0 mm 0 39 in D 0 3 0 mm 0 0 12 in E Align the oil separator and crankcase marks with each other F Fasten the sidestand switch lead and stator coil assembly lead with the clamp G Fasten the air filter case drain hose with the clamp H Route the air filter case drain hose between the muffler chamber and the frame ...

Page 82: ...CABLE ROUTING 2 55 Air induction system solenoid ...

Page 83: ...be pres ent between the air induction system hose and the air filter case C Insert the air induction system hose air filter case air cut off valve into the base of the air cut off valve D Point the end of the clamp to the inside E Point the end of the clamp obliquely downward F 60 G 30 H Clamp installation range I Install the air induction system hose air cut off valve air induction system pipe so...

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

Page 85: ...HE FRONT BRAKE PADS 3 12 ADJUSTING THE REAR DRUM BRAKE 3 13 CHECKING THE REAR BRAKE SHOES 3 14 CHECKING THE FRONT BRAKE HOSE 3 14 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 14 CHECKING THE WHEELS 3 15 CHECKING AND TIGHTENING THE SPOKES 3 15 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 17 CHECKING THE SWINGARM OPERATION 3 17 LUBRICATING THE SWINGARM 3 17 ADJUSTING THE DRIVE CHAIN SLACK 3 18 LUB...

Page 86: ...KE LIGHT SWITCH 3 24 CHECKING AND LUBRICATING THE CABLES 3 24 CHECKING THE THROTTLE GRIP 3 24 CHECKING AND CHARGING THE BATTERY 3 25 CHECKING THE FUSES 3 25 REPLACING THE HEADLIGHT BULB 3 25 ADJUSTING THE HEADLIGHT BEAM 3 26 ...

Page 87: ...re special tools data and technical skills EAS2RD1004 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM EAS2RD1005 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean ...

Page 88: ...0000 mi 13 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 500 km 300 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing play and steer ing for roughness Lubricate with lith ium soap based grease Every 20000 km 12000 mi 15 Chassis fasteners Make sure...

Page 89: ...of the brake master cylinder and caliper and change the brake fluid Replace the brake hose every four years and if cracked or damaged 22 Shock absorber assemblies Check operation and shock absorbers for oil leakage 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter element Replace 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubrica...

Page 90: ... case breather hose fuel pump case fuel tank 2 Fuel hose fuel pump fuel rail 3 Fuel hose pressure regulator fuel tank 4 Fuel tank breather hose 5 Cracks damage Replace Loose connections Connect properly NOTICE ECA14940 Make sure the fuel tank breather hose is rout ed correctly 3 Check Fuel hose pressure regulator fuel tank lo cation TIP Make sure that the fuel hose 1 is located be low the frame as...

Page 91: ...VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Spark plug cap Spark plug Exhaust...

Page 92: ...ned Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion d Measure the valve clearance again e If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 5 Install Exhaust tappet cover 1 O ring 2 6 Install Intake tappet cover O ring Spark plug Spark plug cap Thickness ga...

Page 93: ...Y JOINT 1 Remove Throttle body Refer to THROTTLE BODY on page 6 9 2 Check Throttle body joint 1 Cracks damage Replace 3 Install Throttle body Refer to THROTTLE BODY on page 6 9 EAS20600 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume 1 Adjust Exhaust gas volume a Turn the main switch to OFF b Connect the self diagnosis sig...

Page 94: ...ton i Release DOWN and UP buttons j Turn the main switch to OFF k Disconnect the FI diagnostic tool and install the self diagnosis signal coupler cap EAS21081 CHECKING THE EXHAUST SYSTEM The following procedure applies to the exhaust pipe and gasket 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 2 Check Exhaust pipe 1 Muffler 2 Cracks damage Replace Gas...

Page 95: ... Air filter case cover 1 3 Check Air filter element 1 Dirt damage Replace TIP Replace the air filter element every 20000 km 12500 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter case cover NOTICE ECA2RD1018 Never operate the engine without the air filter element installed Failure to install the air fil ter element ma...

Page 96: ...in tensioner cap 1 2 Check Rod 1 Check if the rod end 1 is flush with the ad juster end 2 Not flush Adjust 3 Adjust Timing chain tension a Loosen the timing chain tensioner locknut 1 b Turn the adjuster 2 in or out until the rod end 3 is flush with the adjuster end 2 c Tighten the timing chain tensioner locknut 1 4 Install Timing chain tensioner cap Clutch lever free play 5 0 10 0 mm 0 20 0 39 in ...

Page 97: ...r free play is ob tained c Tighten the locknut 7 Install Crankcase cover left Refer to GENERATOR on page 5 46 8 Install Spark plug Spark plug cap EAS2RD1020 CHECKING THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check the brake system Refer to FRONT BRAKE on page 4 17 and REAR BRAKE on page 4 30 TIP Drive on the dry road operate the front and rear brakes separately and che...

Page 98: ...fluid level make sure the top of the brake fluid reservoir is horizontal EAS21170 ADJUSTING THE FRONT DISC BRAKE 1 Check Brake lever free play a Out of specification Adjust 2 Adjust Brake lever free play a Loosen the locknut 1 b Turn the adjusting screw 2 in direction a or b until the specified brake lever free play is obtained c Tighten the locknut 1 WARNING EWA13050 A soft or spongy feeling in t...

Page 99: ...justing bolt 2 in direction a or b until the specified brake pedal position is obtained c Tighten the locknut 1 to specification 3 Check Brake pedal free play a Out of specification Adjust 4 Adjust Brake pedal free play a Turn the adjusting nut 1 in direction a or b until the specified brake pedal free play is ob tained Brake pedal position 20 0 mm 0 79 in Direction a Brake pedal is lowered Direct...

Page 100: ...on page 4 17 EAS21340 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA13100 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty 1 Remove Reservoir cap TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overfl...

Page 101: ...ified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS21670 CHECKING THE 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 TIP After a tire or wheel has been changed or re placed...

Page 102: ...ICLE WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire 1 Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 175 kPa 1 75 kgf cm2 25 psi Rear 200 kPa 2 00 kgf cm2 29 psi Loading condition 90 150 kg 198 331 lb Front 200 kPa 2 00 kgf cm...

Page 103: ...y have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS2RD1021 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bea...

Page 104: ...ck a Loosen wheel axle nut 1 b Loosen the brake pedal free play adjusting nut and tension bar nut c Loosen both locknuts 2 d Turn the adjusting bolts 3 in direction a or b until the specified drive chain slack is ob tained TIP To maintain the proper wheel alignment adjust both sides evenly Align matching marks c with the same posi tion e Tighten the wheel axle nut to specification f Tighten the lo...

Page 105: ...Adjust Steering head a Remove the lock washer 1 upper ring nut 2 and rubber washer 3 b Tighten the lower ring nut 4 to specification with a steering nut wrench 5 TIP Set the torque wrench at a right angle to the steering nut wrench c After fully loosening the lower ring nut tighten it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the ste...

Page 106: ...ring contact point of the sides tand EAS2RD1038 CHECKING THE CENTERSTAND 1 Check Centerstand operation Check that the centerstand moves smoothly Rough movement Repair or replace EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand EAS2RD1033 CHECKING THE SIDESTAND SWITCH Refer to ELECTRICAL COMPONENTS on page 7 51 EAS21531 CHECKING TH...

Page 107: ...just Spring preload a Turn the adjusting ring 1 in direction a or b b Align the desired position on the adjusting ring with the stopper 2 EAS20731 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle upright on the centerstand 2 Start the engine warm it up for several min utes and then turn it off Before checking the engine oil level wait a few minutes until t...

Page 108: ...d then turn it off 2 Place a container under the engine oil drain bolt 3 Loosen Bleeder bolt 1 Oil filter cover bolt 2 TIP Do not remove the bolt 4 Remove Engine oil level gauge Oil drain bolt oil tank side 1 Oil drain bolt crankcase side 2 5 Drain Engine oil completely from the oil tank and the crank case 6 If the oil filter element is also to be replaced perform the following procedure a Remove ...

Page 109: ... bolt 1 NOTICE ECA2RD1002 Engine start up with the oil check bolt re moved will cause an oil spout Check with the oil check bolt loosened without fail b Start the engine and check to see if oil seeps out while idling the engine for about one min ute NOTICE ECA2RD1003 Any inspection must be conducted at engine idling speed Do not rev up the engine c If no oil seeps out check the engine oil pas sage...

Page 110: ...use the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS30890 CHECKING THE THROTTLE GRIP 1 Check Throttle cable Damage de...

Page 111: ...direction a or b until the specified throttle grip free play is ob tained c Tighten the locknut WARNING EWA2RD1001 After adjusting the throttle grip free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS21760 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 7 60 EAS...

Page 112: ... the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Hook Headlight bulb holder 8 Install Headlight bulb cover 9 Connect Headlight coupler 10 Install Headlight unit assembly Screw EAS21800 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Loosen the adjusting screw 1 and move the...

Page 113: ...PERIODIC MAINTENANCE 3 27 1 a b ...

Page 114: ...PERIODIC MAINTENANCE 3 28 ...

Page 115: ... BRAKE DISC 4 22 REPLACING THE FRONT BRAKE PADS 4 23 REMOVING THE FRONT BRAKE CALIPER 4 24 DISASSEMBLING THE FRONT BRAKE CALIPER 4 24 CHECKING THE FRONT BRAKE CALIPER 4 25 ASSEMBLING THE FRONT BRAKE CALIPER 4 25 INSTALLING THE FRONT BRAKE CALIPER 4 26 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 27 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 INSTALLI...

Page 116: ...K ABSORBER ASSEMBLIES 4 49 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 49 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 49 REMOVING THE SWINGARM 4 49 CHECKING THE SWINGARM 4 50 ADJUSTING THE THRUST CLEARANCE 4 50 INSTALLING THE SWINGARM 4 51 CHAIN DRIVE 4 53 REMOVING THE DRIVE CHAIN 4 53 CHECKING THE DRIVE CHAIN 4 53 CHECKING THE DRIVE SPROCKET 4 54 CHECKING THE REAR WHEEL SPROCKET 4 54 CHECKING T...

Page 117: ...L CHASSIS Removing the seat and side covers Order Job Parts to remove Q ty Remarks 1 Seat 1 2 Side cover right 1 3 Side cover left 1 Unlock using the key 1 2 3 7 Nm 0 7 m kgf 5 1 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf ...

Page 118: ...e battery and battery box Order Job Parts to remove Q ty Remarks Seat 1 Battery band 1 2 Clamp 1 Remove the battery lead 3 Battery connector 1 4 Battery 1 5 Battery box 1 1 3 4 2 5 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 119: ... 4 ECU coupler 1 Disconnect 5 Turn signal hazard relay coupler 1 Disconnect 6 Lean angle sensor 1 7 Turn signal hazard relay 1 8 ECU engine control unit 1 9 Fuel pump relay coupler headlight relay on off coupler 1 1 Disconnect 10 Fuel pump relay 1 11 Headlight relay on off 1 12 Intake air temperature sensor coupler 1 Disconnect 13 Intake air temperature sensor 1 1 2 3 4 5 6 7 8 9 10 11 12 LT LT 2 ...

Page 120: ...ht 2 2 Remove Side cover left 1 TIP Insert the key into the lock release cylinder and unlock by turning it clockwise a EAS2RD1030 INSTALLING THE SIDE COVERS 1 Install Side cover right 1 Bolt 2 2 Install Side cover left 1 2 1 1 a Side cover right bolt 7 Nm 0 7 m kgf 5 1 ft lbf T R 1 1 2 1 ...

Page 121: ...emove Q ty Remarks 1 Speedometer cable 1 2 Axle holder nut 2 Loosen 3 Wheel axle nut 1 4 Washer 1 5 Collar 1 6 Wheel axle 1 7 Front wheel assembly 1 8 Speedometer gear unit assembly 1 9 Brake disc 1 LT 1 2 3 4 5 6 7 8 9 23 Nm 2 3 m kgf 17 ft Ibf 104 Nm 10 4 m kgf 75 ft Ibf 9 Nm 0 9 m kgf 6 5 ft Ibf ...

Page 122: ...WHEEL 4 6 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Clutch retainer 1 3 Meter clutch 1 4 Oil seal 1 5 Bearing 1 6 Spacer 1 7 Bearing 1 8 Front wheel 1 1 2 3 4 5 6 7 8 ...

Page 123: ...ce Loose Tighten Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 15 TIP After tightening the spokes measure the front wheel runout 4 Measure Front wheel radial runout a Front wheel lateral runout b Over the specified limits Replace 5 Check Collar Damage wear Replace WARNING EWA2RD1007 Immediately after tires are replaced with new ones drive carefully until getting used to the travelling feel...

Page 124: ...al EAS21940 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check Speedometer clutch Bends damage wear Replace 2 Check Speedometer drive gear Speedometer driven gear Damage wear Replace EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balan...

Page 125: ... d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL The following procedure applies to both of the brake discs 1 Lubricate Oil seal lip 2 Install Speedometer gear unit 1...

Page 126: ...ebar s several times and check if the front fork rebounds smooth ly TIP Make sure that an arrow of the axle holder points toward the front A Tighten the axle holder nut at the front side first and then the rear side 5 Install Speedometer cable Wheel axle nut 104 Nm 10 4 m kgf 75 ft lbf Axle holder nut 9 Nm 0 9 m kgf 6 5 ft lbf c d T R A 1 1 ...

Page 127: ...ompression spring 1 4 Nut washer 1 1 5 Locknut adjusting bolt 2 2 Loosen 6 Wheel axle nut washer 1 1 7 Wheel axle 1 8 Spacer 1 9 Chain puller left chain puller right 1 1 10 Drive chain 1 11 Rear wheel assembly 1 12 Brake shoe plate 1 1 4 2 3 5 6 7 8 9 11 12 10 5 9 19 Nm 1 9 m kgf 14 ft Ibf 129 Nm 12 9 m kgf 93 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf ...

Page 128: ...Removing the rear wheel sprocket Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Hub dust seal 1 3 Hub stopper 2 4 Rear wheel sprocket 1 5 Drive hub 1 6 Drive hub damper 6 1 2 3 4 5 6 26 Nm 2 6 m kgf 19 ft Ibf LT ...

Page 129: ...REAR WHEEL 4 13 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Bearing 1 2 Spacer 1 3 Flange spacer 1 4 Oil seal 1 5 Bearing 1 6 Bearing 1 1 2 3 4 5 6 ...

Page 130: ...h the rear wheel forward and remove the drive chain from the rear wheel sprocket 6 Remove Brake shoe plate EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage Replace Rear wheel drive hub damper 2 Damage wear Replace EAS22101 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearing Oil seal Refer to CHECKING THE FRONT WHEEL on page 4 7 2 Check Tire Re...

Page 131: ...surfaces that contact the sprocket f Install the new rear wheel sprocket TIP Tighten the locknuts in stages and in a criss cross pattern g Bend the lock washer tabs h Install the hub stopper hub dust seal and new circlip EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance w...

Page 132: ...lack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 5 Tighten Wheel axle nut 6 Install Tension bar Brake rod 7 Adjust Brake pedal free play Refer to ADJUSTING THE REAR DRUM BRAKE on page 3 13 Recommended lubricant Lithium soap based grease Drive chain slack 30 0 40 0 mm 1 18 1 57 in Wheel axle nut 129 Nm 12 9 m kgf 93 ft lbf T R ...

Page 133: ...front brake pads Order Job Parts to remove Q ty Remarks 1 Brake hose holder 1 2 Caliper support bolt 2 3 Caliper assembly 1 4 Brake pad shim 2 2 5 Pad support 2 6 Pad spring 1 S S 27 Nm 2 7 m kgf 20 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 1 2 2 3 4 4 4 5 5 6 ...

Page 134: ...pring 1 1 3 Front brake light switch 1 4 Brake master cylinder reservoir cap 1 5 Brake master cylinder reservoir diaphragm holder 1 6 Brake master cylinder reservoir diaphragm 1 7 Union bolt 1 8 Gasket 2 9 Brake hose 1 10 Master cylinder holder 1 11 Master cylinder 1 S S 30 Nm 3 0 m kgf 22 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 7 8 9 11 7 Nm 0 7 m kgf 5 1 ft Ibf 10 4 5 6 1 5 Nm 0 15 m kgf 1 1 ft I...

Page 135: ...FRONT BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 BF BF S 1 ...

Page 136: ...ING THE HYDRAULIC BRAKE SYSTEM on page 3 14 1 Brake hose holder 1 2 Union bolt 1 3 Gasket 2 4 Brake hose 1 5 Caliper support bolt 2 6 Caliper assembly 1 7 Caliper bracket 1 S S 10 Nm 1 0 m kgf 7 2 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 27 Nm 2 7 m kgf 20 ft Ibf 40 Nm 4 0 m kgf 29 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf 1 2 3 4 5 5 6 7 ...

Page 137: ...ont brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 5 Brake caliper cylinder 1 6 Nm 0 6 m kgf 4 3 ft Ibf 1 1 2 3 3 4 5 BF BF S S ...

Page 138: ...30 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 5 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc runout turn the handlebar to the left or right to ...

Page 139: ...him 2 Pad support 3 Pad spring 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Pad spring Pad support Shim onto the brake pads Brake pad TIP Always install new brake pads brake pad shims and brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed s...

Page 140: ... the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 EAS22290 REMOVING THE FRONT BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Gasket 2 Brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22321 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Br...

Page 141: ...iper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22401 ASSEMBLING THE FRONT BRAKE CALIPER WARNING EWA13621 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new...

Page 142: ...g leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake f...

Page 143: ...r cylinder by pressing the projection on the brake light switch 2 Remove Union bolt 1 Gasket 2 Brake hose 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passage 2 Brake master cylinder body Obstruc...

Page 144: ...er bolt 2 Install Gasket Brake hose Union bolt WARNING EWA2RD1011 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 33 TIP While holding the brake hose tighten the union bolt as shown 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 ...

Page 145: ...or lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 6 Check Brake lever...

Page 146: ... BRAKE Disassembling the rear brake Order Job Parts to remove Q ty Remarks 1 Brake shoe kit 1 2 Brake camshaft lever 1 3 Indicator plate 1 4 Oil seal 1 5 Brake camshaft 1 6 Camshaft shim 1 2 1 3 4 5 6 9 Nm 0 9 m kgf 6 5 ft Ibf F F ...

Page 147: ...not allow oil or grease on the brake shoes TIP Replace the brake shoes as a set if either is worn to the wear limit 3 Measure Brake drum inside diameter b Out of specification Replace the hub 4 Check Brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Replace Lightly and evenly polish the scratches with an emery cloth 5 Check Brake c...

Page 148: ...t so its punch mark is positioned as shown b Align the projection a on the indicator plate with the notch b in the brake camshaft c Check that the brake shoes are properly po sitioned 2 Install Rear wheel Refer to REAR WHEEL on page 4 11 1 2 a b ...

Page 149: ... Throttle cable 1 2 1 1 8 Throttle grip 1 9 Clutch cable 1 10 Decompression cable 1 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch switch 1 14 Lever holder decompression lever 1 1 15 Cap 4 16 Upper handlebar holder 2 7 Nm 0 7 m kgf 5 1 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 1 1 2 2 3 4 5 6 6 7 8 9 10 11 13 11 12 14 14 15 16 7 Nm 0 7 m kgf 5 1 ft Ibf 2 3 Nm 0 23 m kgf ...

Page 150: ... Q ty Remarks 17 Handlebar 1 18 Washer plain 2 19 Lower handlebar holder 2 20 Cover 2 7 Nm 0 7 m kgf 5 1 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 17 19 19 20 20 7 Nm 0 7 m kgf 5 1 ft Ibf 2 3 Nm 0 23 m kgf 1 7 ft Ibf 3 5 Nm 0 35 m kgf 2 5 ft Ibf 18 ...

Page 151: ... of it falling over 2 Install Handlebar 1 Upper handlebar holder 2 NOTICE ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position TIP Align the match marks a on the handlebar with the upper surface of the lower handlebar holder T...

Page 152: ...e handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried 8 Install Clutch cable 1 Decompression cable 2 TIP Apply lithium soap based grease to the end of the cable before installation 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE P...

Page 153: ...xcept for AUS 4 Right reflector 1 For AUS 5 Left reflector 1 For AUS 6 Upper bracket pinch bolt 2 Loosen 7 Lower bracket pinch bolt 4 Loosen 8 Fork boot lock screw 1 Loosen 9 Front fork leg left 1 10 Front fork leg right 1 16 Nm 1 6 m kgf 12 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 40 Nm 4 0m kgf 29 ft Ibf 1 2 3 4 6 7 9 10 10 Nm 1 0 m kgf 7 2 ft Ibf 2 5 Nm 0 25 m kgf 1 8 ft Ibf 8...

Page 154: ...k spring 1 7 Axle holder 1 8 Damper rod assembly bolt 1 9 Dust seal 1 10 Oil seal clip 1 11 Inner tube 1 12 Oil seal 1 13 Washer 1 14 Slide metal 1 15 Piston metal 1 16 Damper rod rebound spring 1 1 17 Oil lock piece 1 18 Outer tube 1 23 Nm 2 3 m kgf 17 ft Ibf 28 Nm 2 8 m kgf 20 ft Ibf 9 Nm 0 9 m kgf 6 5 ft Ibf 1 3 4 5 6 2 7 8 9 10 11 12 13 14 15 16 17 18 ...

Page 155: ...ng the upper and lower brack et pinch bolts support the front fork leg TIP Loosen the cap bolt with a 17 mm 0 67 in hexa gon wrench 5 4 Remove Front fork leg Dust boot EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the outer tube several times while drain ing the fork oil 2 Remove Dust seal Oil seal clip 1 with ...

Page 156: ...ube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil lock piece Damage Replace 4 Check Cap bolt Damage wear Replace EAS23021 ASSEMBLING ...

Page 157: ...le 3 4 Install Washer Oil seal 1 with the fork seal driver weight and fork seal driver attachment ø35 NOTICE ECA14220 Make sure the numbered side of the oil seal faces up TIP Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag...

Page 158: ...1 Spring seat 2 Cap bolt 3 along with the O ring 4 TIP Install the spring with the smaller pitch a fac ing up Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 342 034 2 New 1 New 1 Quantity 204 0 cm3...

Page 159: ...pinch bolt 1 Cap bolt 2 TIP Tighten the cap bolt with a 17 mm 0 67 in hexa gon wrench 3 Upper bracket pinch bolt 4 Fork boot lock screw 5 WARNING EWA13680 Make sure the brake hoses are routed prop erly Lower bracket pinch bolt 17 Nm 1 7 m kgf 12 ft lbf Cap bolt 23 Nm 2 3 m kgf 17 ft lbf Upper bracket pinch bolt 16 Nm 1 6 m kgf 12 ft lbf Fork boot lock screw 2 5 Nm 0 25 m kgf 1 8 ft lbf T R T R T R...

Page 160: ...in headlight body Disconnect 3 Headlight body 1 4 Front right turn signal light front left turn signal light 1 1 5 Speedometer cable Tachometer cable 1 1 6 Speedometer tachometer 1 1 7 Meter stay 1 8 Horn lead 1 Disconnect 9 Horn 1 10 Bracket 1 11 Light stay left light stay right 1 1 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 1 2 2 2 3 4 4 5 6 6 7 8 9 10 11 11 8 ...

Page 161: ...y 1 Steering stem nut 1 2 Washer 1 3 Upper bracket 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Ball race cover 1 9 Ball race 1 1 10 Bearing 1 1 11 Lower bracket 1 12 Bearing 2 1 13 Ball race 2 1 14 Ball race 3 1 15 Ball race 4 1 16 Dust seal 1 38 Nm 3 8 m kgf 27 ft Ibf 1st 18 Nm 1 8 m kgf 13 ft Ibf 2nd 110 Nm 11 m kgf 80 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 162: ...Bearing 1 Bearing race 2 Damage pitting Replace 3 Replace Bearing Bearing race a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing races 3 from the lower bracket with a floor chisel 4 and hammer c Install new dust seals and new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged T...

Page 163: ...pper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 19 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork leg Refer to FRONT FORK on page 4 37 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem nut 110...

Page 164: ... 1 5 Pivot shaft nut 2 Remove either one of the right and left 6 Pivot shaft 1 7 Swingarm 1 8 Collar 1 9 Tension bar 1 10 Washer 1 Only models with the mark stamped on the frame 11 Dust cover 2 12 Shim 1 Install the required number of them depend ing on the thrust clearance 19 Nm 1 9 m kgf 14 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 104 Nm 10 4 m kgf 75 ft Ibf 104 Nm 10 4 m kgf ...

Page 165: ... Washer Rear shock absorber assembly lower nut 2 Install Washer Grab bar Washer Rear shock absorber assembly upper nut TIP When installing the rear shock absorber assem bly lift up the swingarm 3 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut 4 Install Rear right footrest EAS23340 REMOVING THE SWINGARM 1 Stand the vehicle on a level surface WARNING EWA13120 S...

Page 166: ... damage Replace 2 Check Pivot shaft nut Damage wear Replace 3 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 4 Check Collar 1 Dust cover 2 Bearing 3 Oil seal 4 Bearing 5 Collar 6 Damage wear Replace EAS2RD1028 ADJUSTING THE THRUST CLEARANCE 1 Measure Collar head pipe length a Out of specification Replace 2 Mea...

Page 167: ...re that the dimension a is 1 7 mm 0 07 in or more If the dimension is less than 1 7 mm 0 07 in reinstall the pivot shaft Install a washer 1 to only points b that are stamped on the frame 3 Install Rear shock absorber assembly Rear wheel Refer to REAR WHEEL on page 4 11 Size b swingarm pivot shaft length thickness of both bear ings 1 thickness of cover 2 196 7 196 9 mm 7 74 7 75 in Thrust clearance...

Page 168: ...REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 4 52 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 Drive chain slack 30 0 40 0 mm 1 18 1 57 in ...

Page 169: ...n a Measure the length a between the inner sides of the pins and the length b between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length c of the 15 link section of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When measurin...

Page 170: ...nd rear wheel sprocket as a set Bent teeth Replace the drive chain drive sprocket and rear wheel sprocket as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 EAS23490 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive...

Page 171: ...e 3 18 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 30 0 40 0 mm 1 18 1 57 in ...

Page 172: ...CHAIN DRIVE 4 56 ...

Page 173: ...AFTS AND ROCKER ARMS 5 15 VALVES AND VALVE SPRINGS 5 16 REMOVING THE VALVES 5 17 CHECKING THE VALVES AND VALVE GUIDES 5 17 CHECKING THE VALVE SEATS 5 19 CHECKING THE VALVE SPRINGS 5 20 INSTALLING THE VALVES 5 21 CYLINDER AND PISTON 5 23 REMOVING THE PISTON 5 24 CHECKING THE CYLINDER AND PISTON 5 24 CHECKING THE PISTON RINGS 5 25 CHECKING THE PISTON PIN 5 26 CHECKING THE TIMING CHAIN GUIDES 5 26 IN...

Page 174: ...TALLING THE GENERATOR 5 47 CRANKCASE 5 48 DISASSEMBLING THE CRANKCASE 5 50 CHECKING THE CRANKCASE 5 50 CHECKING THE TIMING CHAIN AND CRANKSHAFT SPROCKET 5 50 CHECKING THE BEARING 5 50 CHECKING THE OIL STRAINER 5 50 ASSEMBLING THE CRANKCASE 5 50 CRANKSHAFT ASSEMBLY 5 52 REMOVING THE CRANKSHAFT ASSEMBLY 5 53 CHECKING THE CRANKSHAFT ASSEMBLY 5 53 INSTALLING THE CRANKSHAFT ASSEMBLY 5 54 TRANSMISSION 5...

Page 175: ...zes WARNING EWA2RD1003 To prevent spark generation spark plug lead should be grounded before cranking by the kickstarter b If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate c If the compression pressure is below the min imum specification pour a teaspoonful en gine of oil into the spa...

Page 176: ...4 Circlip tachometer cable 1 1 5 Decompression cable 1 6 Front right footrest 1 7 Brake pedal 1 8 Rear brake light switch 1 Remove from the holder 9 Engine protector 1 10 Oil hose 1 1 Remove the oil tank side 11 Oil hose 2 1 Remove the crankcase side 12 Cylinder head breather hose 1 10 Nm 1 0 m kgf 7 2 ft Ibf 1 3 9 10 11 10 Nm 1 0 m kgf 7 2 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 60 Nm 6 0 m kgf 43 ft Ib...

Page 177: ... 4 Drive sprocket 1 5 Drive chain 1 Loosen the rear wheel axle nut to make the drive chain slack before removal 6 Front left footrest 1 7 Shift pedal 1 8 Oil separator 1 9 Clutch cable 1 Disconnect 10 Breather hose 1 Disconnect 11 Spark plug cap 1 12 Engine temperature sensor coupler 1 Disconnect 13 Stator coil assembly coupler 2 Disconnect 14 Rectifier regulator coupler 1 Disconnect 9 10 Nm 1 0 m...

Page 178: ...unt front right 1 5 Engine mount front left 1 6 Engine mount upper 1 7 Engine 1 1 2 3 4 5 6 7 60 Nm 6 0 m kgf 43 ft Ibf 64 Nm 6 4m kgf 46 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 42 Nm 4 2 m kgf 30 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 60 Nm 6 0 m kgf 43 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf LT LT ...

Page 179: ...t rear side Engine mount upper nut Engine mounting nut upper side 3 Install Shift pedal 1 TIP The angle b of the shift pedal end must fall within 6 with reference to the line passing through a shown in the illustration Engine mount front bolt 35 Nm 3 5 m kgf 25 ft lbf LOCTITE Engine mounting nut front side 64 Nm 6 4 m kgf 46 ft lbf Engine mounting nut front lower side 60 Nm 6 0 m kgf 43 ft lbf Eng...

Page 180: ...Viewer plug 1 9 Timing chain tensioner cap 1 10 Timing chain tensioner assembly 1 11 Camshaft sprocket 1 12 Timing chain 1 13 Camshaft 1 14 Cylinder head assembly 1 15 Gasket 1 16 Dowel pin 2 LT 1 3 4 9 10 5 6 7 8 12 11 13 14 15 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 25 Nm 2 5 m kgf 18 ft Ibf 38 Nm 3 8 m kgf 27 ft Ibf 38 Nm 3 8 m ...

Page 181: ...ly 1 TIP Loosen bolts and nuts in a crisscross pattern Loosen each bolt and nut 1 2 of a turn at a time After all of the bolts and nuts are fully loosened remove them 5 Loosen Camshaft sprocket bolt TIP While holding the AC magneto 1 with the rotor holding tool 2 loosen the camshaft sprocket bolt 6 Remove Timing chain tensioner cap Timing chain tensioner assembly Camshaft sprocket bolt 1 Timing ch...

Page 182: ...linder head a Place a straightedge 1 and a thickness gauge 2 across the mating surface of the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times e When t...

Page 183: ...IMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place EAS24230 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head gasket Dowel pin 2 Install Cylinder head 1 Camshaft lobe dimensions Lobe height Intake 38 860 38 960 mm 1 5299 1 5339 in Limit 38 850 mm 1 5295 in Base circle diameter Intake 32 170 32 270 mm 1 2665 1 2705 in Limit 32 160 mm 1 2661 in Lobe height ...

Page 184: ...in 1 Camshaft sprocket 2 TIP Align the camshaft with the dowel pin hole a on the camshaft sprocket Install the timing chain so that the punch mark b on the camshaft sprocket is flush with the end surface of the cylinder head and the dowel pin is perpendicular to the end surface of the cylinder head 7 Install Plate 1 Camshaft sprocket bolt 2 TIP Temporarily tighten the camshaft sprocket bolt 8 Inst...

Page 185: ...mshaft sprocket bolt 12 Install Crankcase cover left Refer to GENERATOR on page 5 46 13 Install Viewer plug 1 TIP Align the marked line a on the viewer plug with the end surface of the cylinder head rear sec tion 14 Loosen Locknut rocker arm Adjuster rocker arm Refer to ROCKER ARMS on page 5 13 15 Clean the mating surfaces between the cylin der head cover assembly and the cylinder head 16 Apply Se...

Page 186: ...age 3 5 19 Adjust Cam chain tensioner TIP Screw until the end surface of the screw a be comes flush with the end surface of the rod b and tighten the locknut before installing the tim ing chain tensioner cap 20 Install Timing chain tensioner cap Cylinder head cover nut 10 mm 1 4 38 Nm 3 8 m kgf 27 ft lbf Cylinder head cover nut 8 mm 5 6 20 Nm 2 0 m kgf 14 ft lbf Cylinder head cover bolt 6 mm 7 9 1...

Page 187: ...ENGINE REMOVAL on page 5 2 Cylinder head Refer to CYLINDER HEAD on page 5 6 1 Locknut adjuster 2 2 2 Lock washer 2 3 Rocker arm shaft intake 1 4 Rocker arm intake 1 5 Rocker arm shaft exhaust 1 6 Rocker arm exhaust 1 M M M E 1 1 2 3 4 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf 27 Nm 2 7 m kgf 20 ft Ibf 27 Nm 2 7 m kgf 20 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 188: ... rocker arms and rocker arm shafts 1 Check Rocker arm Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter a Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 ...

Page 189: ... 2 Lubricate Rocker arm shaft 3 Install Rocker arm 1 Rocker arm shaft 2 TIP Install the rocker arm shafts with the slide ham mer bolt 3 TIP Make sure that a recess in the rocker arm shaft is aligned with the tightening bolt hole in the cyl inder head 4 Install Lock washer 1 Lock washer bolt 2 TIP Bend the lock washer tab along a flat side of the bolt Rocker arm to rocker arm shaft clearance 0 009 ...

Page 190: ...emarks Engine Refer to ENGINE REMOVAL on page 5 2 Cylinder head camshaft Refer to CYLINDER HEAD on page 5 6 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring outer 2 4 Valve spring inner 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Valve spring seat 2 9 Valve guide 2 M 1 1 2 2 4 4 3 3 5 6 7 7 8 8 M M M M 9 9 M M ...

Page 191: ...ressing the valve spring with the valve spring compressor 2 3 Remove Valve spring retainer 1 Outer valve spring 2 Inner valve spring 3 Valve 4 Valve stem seal 5 Valve spring seat 6 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guid...

Page 192: ...he proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Valve stem runout Out of specification Replace the valve TIP When installing a new valve always replace the valve gu...

Page 193: ...Where the valve seat and valve face contacted one another the blue layout fluid will have been removed 4 Lap Valve face Valve seat TIP After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face NOTICE ECA13790 Do not let the lapping compound enter the gap between the valve stem and th...

Page 194: ...ar impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring I...

Page 195: ...lve 2J2 Exhaust valve 5A8 Install the valve springs with the larger pitch a facing up Inner spring Installed compression spring force intake 119 64 N 12 20 kgf 26 90 lbf Installed compression spring force exhaust 119 64 N 12 20 kgf 26 90 lbf Installed length intake 38 00 mm 1 50 in Installed length exhaust 38 00 mm 1 50 in Outer spring Installed compression spring force intake 160 83 N 16 40 kgf 3...

Page 196: ...e valve spring with the valve spring compressor 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve a Larger pitch b Smaller pitch Valve spring compressor 90890 01253 2 1 2 ...

Page 197: ...nder head Refer to CYLINDER HEAD on page 5 6 1 Timing chain guide intake side 1 2 Cylinder O ring 1 1 3 Dowel pin 2 4 Cylinder gasket 1 5 Timing chain guide exhaust side 1 6 Piston pin clip 2 7 Piston pin 1 8 Piston 1 9 Piston ring set 1 E E 1 2 3 4 5 6 6 7 8 9 3 8 Nm 0 8 m kgf 5 8 ft Ibf 38 Nm 3 8 m kgf 27 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf E E E 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 198: ... gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylin der bore gauge TIP Measure the cylinder bore C by taking sid...

Page 199: ...ston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest a Piston skirt diameter D b 7 2 mm 0 28 in from the bottom edge of the piston Diameter 86 948 86 963 mm 3 ...

Page 200: ...CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide intake side 1 Timing chain guide exhaust side 2 Damage wear Replace EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 Piston ring end gaps Top ring End gap installed 0 30 0 50 mm 0 0118 0 0197 in Limit 0 80 mm 0 0315 in 2nd ring End gap installed 0 30 0 50 mm 0 0118 0 019...

Page 201: ...recommended lubricant 4 Offset Piston ring end gap 5 Install Timing chain guide exhaust side 6 Install O ring Cylinder gasket 1 Dowel pin Cylinder 2 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil 3 1 2 4 5 New 1 2 3 a a Top ring b ...

Page 202: ...gine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 Front right footrest Refer to ENGINE REMOVAL on page 5 2 1 Oil filter cover 1 2 Oil filter element 1 3 Kick crank 1 4 Crankcase cover right 1 5 Gasket 1 6 Dowel pin 2 3 4 5 6 1 2 6 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf ...

Page 203: ...ry drive gear 1 5 Straight key 1 6 Clutch spring 6 7 Pressure plate 1 8 Push rod 2 1 9 Friction plate 8 10 Clutch plate 7 11 Nut Belleville washer 1 1 12 Clutch boss 1 13 Washer 1 14 Clutch housing 1 15 Spacer 1 16 Push rod 1 1 M E 13 1 2 3 4 5 11 8 6 7 10 9 14 16 12 15 60 Nm 6 0 m kgf 43 ft Ibf 60 Nm 6 0 m kgf 43 ft Ibf 9 Nm 0 9 m kgf 6 5 ft Ibf ...

Page 204: ...er shaft Order Job Parts to remove Q ty Remarks Drive sprocket cover Clutch cable Clutch assembly 1 Locknut gasket 1 1 2 Adjuster 1 3 Push lever shaft 1 4 Torsion spring 1 5 Washer 1 6 Oil seal 1 1 2 3 4 5 6 18 Nm 1 8 m kgf 13 ft Ibf E ...

Page 205: ...plies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set TIP Measure the friction plate at four places EAS25111 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as...

Page 206: ...e the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss spline Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace EAS25191 CHECKING THE CLUTCH PUSH RODS...

Page 207: ...drive gear and primary driven gear clutch housing as a set Excessive noise during operation Replace the primary drive gear and primary driven gear clutch housing as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive gear and primary driven gear clutch housing as a set EAS25260 INSTALLING THE CLUTCH 1 Install Clutch housing 1 TIP Align the r...

Page 208: ... a crisscross pattern 8 Check Push lever position The push lever 1 and the match mark a in the crankcase are not aligned with each other as shown in the illustration Correct TIP Push the push lever in the arrow direction and make sure the marks are aligned 9 Adjust Push lever position a Loosen the locknut 1 b Turn the adjuster 2 in or out until the marks are aligned c Hold the adjuster to prevent ...

Page 209: ...NG THE CLUTCH LEVER FREE PLAY on page 3 10 11 Install Drive sprocket cover 12 Install Dowel pin Crankcase cover gasket Crankcase cover right Drive sprocket cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Crankcase cover right bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 T R New T R ...

Page 210: ... Job Parts to remove Q ty Remarks Crankcase cover right Refer to CLUTCH on page 5 28 Clutch Refer to CLUTCH on page 5 28 1 Kick pinion gear 1 2 Circlip washer 1 1 3 Kick idle gear 1 4 Kickstarter assembly 1 5 Washer 1 6 Washer 1 10 Nm 1 0 m kgf 7 2 ft Ibf M 1 2 3 4 6 5 ...

Page 211: ... to remove Q ty Remarks 1 Circlip spring cover 1 1 2 Compression spring 1 3 Ratchet wheel 1 4 Circlip spacer 1 1 5 Torsion spring 1 6 Spring cover 1 7 Circlip washer 1 1 8 Kick gear 1 9 Washer 1 10 Circlip 1 11 Kick axle assembly 1 M E 1 2 3 4 5 6 7 8 9 10 11 M M ...

Page 212: ...ge wear Replace EAS24880 INSTALLING THE KICKSTARTER 1 Install Ratchet wheel 1 Compression spring 2 Spring cover 3 Circlip 4 TIP Align the ratchet wheel and kick axle punch marks with each other a 2 Install Kickstarter assembly 1 TIP Align the ratchet wheel 2 with the stopper 3 and put the torsion spring 4 on the kick spring stopper 5 1 2 1 2 New 1 2 3 4 a 1 2 3 4 5 ...

Page 213: ...to remove Q ty Remarks Crankcase cover right Refer to CLUTCH on page 5 28 Clutch Refer to CLUTCH on page 5 28 1 Oil pump drive gear 1 2 Circlip 1 3 Plate washer 1 4 Oil pump driven gear 1 5 Washer 1 6 Oil pump assembly 1 7 Gasket 1 1 2 3 4 5 6 7 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 214: ...y Remarks 1 Oil pump cover 1 2 Feed side outer rotor 1 3 Feed side inner rotor 1 4 Dowel pin 1 5 Scavenger side outer rotor 1 6 Pump shaft 1 7 Dowel pin 1 8 Scavenger side inner rotor 1 9 Dowel pin 2 10 Oil pump housing 1 E 1 2 3 4 5 6 7 8 9 10 9 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 215: ...rotor to oil pump housing clearance b Oil pump housing to inner rotor and out er rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the recommended lubricant 1 2 3 4 Inner rotor to outer rotor tip clearance 0 070 0 120 mm ...

Page 216: ...nd outer match marks with each other a 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 41 EAS25020 INSTALLING THE OIL PUMP 1 Install Gasket Oil pump 1 NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly 2 Install Oil pump driven gear 1 Plate washer 2 Circlip 3 Recommended lubricant Lithium soap based grease Recommended lubricant Engine oil Oil pump ...

Page 217: ...e shift shaft and stopper lever Order Job Parts to remove Q ty Remarks Clutch Refer to CLUTCH on page 5 28 1 Circlip 1 2 Stopper lever assembly 1 3 Circlip 1 4 Washer 1 5 Shift shaft assembly 1 6 Torsion spring 1 8 Nm 0 8 m kgf 5 8 ft Ibf 1 2 3 5 6 4 ...

Page 218: ...opper lever assembly Bends damage Replace EAS25451 INSTALLING THE SHIFT SHAFT 1 Install Oil seal left side of the crankcase 1 to the crankcase 2 Install Torsion spring Shift shaft 1 Washer left side of the crankcase Circlip left side of the crankcase 2 TIP Lubricate the oil seal lips with lithi um soap based grease Install the torsion spring to the shift shaft 3 Install Stopper lever assembly 1 Ci...

Page 219: ...45 4 Check Shift lever 3 match mark a Shift the gear into 2nd and check for align ment with the match mark b in the shift drum Not aligned Adjust TIP Loosen the locknut 1 and adjust with the ad juster 2 1 2 a 1 2 b a ...

Page 220: ...case cover left 1 2 Gasket 1 3 AC magneto 1 4 Holder 1 5 Oil pipe 1 Remove only the upper bolt 6 Rectifier regulator coupler 1 Disconnect 7 Stator coil assembly coupler 2 Disconnect 8 Stator coil assembly 1 9 Woodruff key 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 6 7 8 9 7 Nm 0 7 m kgf 5 1 ft Ibf 65 Nm 6 5 m kgf 47 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 221: ...apered portion of the crankshaft and the AC magneto hub When installing the AC magneto make sure the woodruff key is properly sealed in the key way of the crankshaft 3 Tighten AC magneto nut 1 TIP While holding the AC magneto with the rotor holding tool 2 tighten the nut Tighten the AC magneto nut in two stages Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 Flywheel pul...

Page 222: ...STARTER on page 5 36 Oil pump Refer to OIL PUMP on page 5 39 Shift shaft Refer to SHIFT SHAFT on page 5 43 AC magneto Refer to GENERATOR on page 5 46 1 Timing chain 1 2 Indicator plate 1 3 Crankshaft sprocket 1 4 Oil strainer cover Gasket 1 1 5 Oil strainer 1 6 Crankcase right 1 7 Cover gasket 1 1 8 Dowel pin 2 9 O ring 1 1 2 3 4 5 6 7 8 8 9 10 Nm 1 0 m kgf 7 2 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12...

Page 223: ...e crankcase Order Job Parts to remove Q ty Remarks 10 Bearing 1 10 10 Nm 1 0 m kgf 7 2 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf LT 7 Nm 0 7 m kgf 5 1 ft Ibf LT E ...

Page 224: ...rankcase Cracks damage Replace Oil delivery passage Obstruction Blow out with compressed air EAS2RD1015 CHECKING THE TIMING CHAIN AND CRANKSHAFT SPROCKET 1 Check Timing chain Crankshaft sprocket Refer to CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET on page 5 9 EAS2RD1016 CHECKING THE BEARING 1 Check Bearing Abnormal sound rough movement looseness Replace EAS24990 CHECKING THE OIL STRAINER 1 Che...

Page 225: ... 3 Install Dowel pin 4 Install Crankcase bolt Stay 1 TIP Tighten the bolts in stages and in a crisscross pattern 5 Install Oil strainer Oil strainer cover Timing chain Crankcase bolt 12 Nm 1 2 m kgf 8 7 ft lbf T R 1 ...

Page 226: ...5 52 EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Separate the crankcase Refer to CRANKCASE on page 5 48 1 Crankshaft assembly 1 2 Oil seal 1 3 Bearing 1 E E E 1 2 3 ...

Page 227: ...ft runout Out of specification Replace the crank shaft assembly TIP Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification Replace the crank shaft assembly 3 Measure Crankshaft width Out of specification Replace the crank shaft assembly 4 Check Bearing Cracks damage wear Replace the bear ing 5 Check Crankshaft passage Obstruction Blow out with compressed air Crankcase sep...

Page 228: ...ion procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer nut until the crankshaft as sembly bottoms against the bearing in the crank case Crankshaft installer pot 90890 01274 Installing ...

Page 229: ...KCASE on page 5 48 1 Stopper cam assembly 1 2 Shift fork guide bar 1 1 3 Shift fork guide bar 2 1 4 Shift drum assembly 1 5 Shift fork 1 C 1 6 Shift fork 2 R 1 7 Shift fork 3 L 1 8 Drive axle assembly 1 9 Main axle assembly 1 LT E E E 1 7 9 8 6 3 4 2 5 LT E E 28 Nm 2 8 m kgf 20 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf E 3 8 Nm 0 38 m kgf 2 8 ft Ibf E 3 8 Nm 0 38 m kgf 2 8 ft Ibf LT E ...

Page 230: ...clip washer 1 1 5 3rd wheel gear 1 6 Circlip washer 1 1 7 5th wheel gear 1 8 Circlip washer 1 1 9 2nd wheel gear 1 10 Drive axle 1 11 Circlip washer 1 1 12 2nd pinion gear 1 13 5th pinion gear 1 14 Circlip washer 1 1 15 3rd pinion gear 1 16 Circlip washer 1 1 17 4th pinion gear 1 18 Main axle 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 17 18 E M M M M M M ...

Page 231: ...ring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratche...

Page 232: ...ngagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlip Damage bends looseness Replace EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Circlip 1 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the gear 2 Align th...

Page 233: ...2 R 4 Shift fork guide bar 1 5 Shift fork guide bar 2 6 Drive axle assembly 7 Main axle assembly 8 2 Install Stopper cam assembly 1 3 Check Shift cam operation Rough movement Reassemble the trans mission TIP By turning the shift cam make sure that the shift fork main axle and drive axle move smoothly d Chamfer side d 3 4 4 5 d 6 1 6 4 3 2 5 7 8 1 ...

Page 234: ...TRANSMISSION 5 60 ...

Page 235: ...ODY 6 7 CHECKING THE FUEL PUMP OPERATION 6 7 INSTALLING THE FUEL PUMP 6 7 INSTALLING THE FUEL TANK 6 7 INSTALLING THE FUEL PUMP CASE 6 8 THROTTLE BODY 6 9 CHECKING THE INJECTOR 6 12 CHECKING THE PRESSURE REGULATOR 6 12 CHECKING THE PRESSURE REGULATOR OPERATION 6 12 ADJUSTING THE THROTTLE POSITION SENSOR 6 12 AIR INDUCTION SYSTEM 6 15 CHECKING THE AIR INDUCTION SYSTEM 6 18 INSTALLING THE AIR INDUCT...

Page 236: ...er Job Parts to remove Q ty Remarks Engine protector Refer to ENGINE REMOVAL on page 5 2 1 Clamp 1 1 2 Rollover valve clamp 1 3 Clamp 2 1 4 Plastic locking tie 1 5 Fuel tank breather hose 1 1 6 Rollover valve 1 7 Fuel tank breather hose 2 1 8 Plug 1 1 5 6 7 8 4 3 2 3 8 Nm 0 38 m kgf 2 8 ft Ibf ...

Page 237: ...the fuel cock side 2 Holder 1 3 Pump case breather hose fuel pump case fuel tank 1 Disconnect the connection at the fuel pump case side 4 Fuel tank breather hose 1 5 Clamp 1 6 Fuel sender coupler 1 Disconnect 7 Fuel tank bolt 1 8 Fuel hose pressure regulator fuel tank 1 Disconnect the connection at the fuel tank side 9 Fuel tank 1 10 Fuel cock 1 11 Fuel sender 1 16 Nm 1 6 m kgf 12 ft Ibf 7 Nm 0 7 ...

Page 238: ...fuel pump case 1 Disconnect the connection at the fuel cock side 2 Holder 1 3 Pump case breather hose fuel pump case fuel tank 1 4 Band 1 5 Fuel pump coupler 1 Disconnect 6 Fuel hose fuel pump fuel rail 1 7 Fuel pump case 1 8 Fuel pump bracket 1 9 Fuel pump gasket 1 10 Fuel pump 1 10 Nm 1 0 m kgf 7 2 ft Ibf 1 3 4 2 6 5 7 9 7 Nm 0 7 m kgf 5 1 ft Ibf 4 0 Nm 0 40 m kgf 2 9 ft Ibf 10 8 ...

Page 239: ...fuel tank filler opening with a hand pump b Turn the fuel cock to the OFF position a c Turn the main switch to ON and 3 seconds later turn it to OFF Repeat these steps sev eral times TIP Repeating main switch turning ON and turn ing OFF allows the fuel in the fuel pump case to be sent to the fuel tank Even after this operation a small amount of fuel remains in the fuel pump case d Start the engine...

Page 240: ... the fuel hose blow away any dirt accumulated around the hose with com pressed air to prevent it from entering the hose or tank 1 Remove Side cover left Refer to GENERAL CHASSIS on page 4 1 2 Remove Fuel pump case WARNING EWA2RD1009 Cover fuel hose connection with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA2RD...

Page 241: ...t the fuel hose is fastened with the holder when installed f Disconnect the pump case breather hose fu el pump case fuel tank 3 at the fuel pump case side g Remove the fuel pump case bolt 4 and band 5 h Remove the fuel pump coupler and fuel hose connector TIP To remove the fuel hose from the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown ...

Page 242: ...mp gasket Install the fuel pump so that it faces the direc tion shown in the illustration Align the projection a on the fuel pump with the cutout on the fuel pump bracket Tighten the fuel pump bolts diagonally in two stages in order shown in the illustration EAS2RD1019 INSTALLING THE FUEL TANK 1 Install Fuel hose Fuel tank NOTICE ECA2RD1012 The fuel hose cannot be properly mounted unless it is sec...

Page 243: ...ly installed unless it is securely connected and the fuel hose holder is installed to correct posi tions The holder 2 is intended to avoid a fuel flow out of the fuel pump casing associated with the fuel hose 3 falling down follow ing the removal of the hose from the fuel cock Make sure that the fuel hose is fas tened with the holder TIP Install the fuel hose securely onto the fuel pump until a di...

Page 244: ...el pump fuel rail 1 3 Negative pressure hose pressure regulator air filter case 1 4 Clamp screw 1 Loosen 5 Clamp screw 1 Loosen 6 Throttle body joint 1 7 Throttle body assembly 1 8 Throttle position sensor coupler 1 Disconnect 9 ISC idle speed control valve valve coupler 1 Disconnect 10 Intake air pressure sensor coupler 1 Disconnect 11 Injector coupler 1 Disconnect 2 0 Nm 0 20 m kgf 1 5 ft Ibf 1 ...

Page 245: ...6 10 Removing the throttle body Order Job Parts to remove Q ty Remarks 12 Cover 1 13 Fuel hose pressure regulator fuel tank 1 2 0 Nm 0 20 m kgf 1 5 ft Ibf 12 13 10 Nm 1 0 m kgf 7 2 ft Ibf 3 0 Nm 0 30 m kgf 2 2 ft Ibf ...

Page 246: ...tle body Order Job Parts to remove Q ty Remarks 1 Fuel rail pressure regulator assembly 1 2 Fuel injector 1 3 Intake air pressure sensor 1 4 Hose 1 5 Throttle position sensor 1 1 2 3 4 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf 3 5 Nm 0 35 m kgf 2 5 ft Ibf ...

Page 247: ...l 6 e Install the fuel tank Refer to FUEL TANK on page 6 1 f Start the engine g Measure the fuel pressure h Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vac uum pressure as described below TIP The vacuum pressure should not exceed 100 kPa 760 mm Hg Faulty Replace fuel pump or throttle body assembly EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR WARNING EWA...

Page 248: ...witch to OFF e Connect the FI diagnostic tool to the self di agnosis signal coupler Refer to DIAGNOSTIC MODE on page 7 25 f While pressing the MODE button turn the main switch to ON TIP DIAG appears on the LCD of the FI diagnostic tool g Select diagnostic code No D 01 h Adjust the position of the throttle position sen sor angle so that 14 20 can appear in the LCD i After adjusting the throttle pos...

Page 249: ...THROTTLE BODY 6 14 ...

Page 250: ...AIR INDUCTION SYSTEM 6 15 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 2 3 4 5 ...

Page 251: ...N SYSTEM 6 16 1 Air filter case 2 Air induction system hose air filter case air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve air induction system pipe 5 Air induction system pipe ...

Page 252: ...r induction system solenoid coupler 1 Disconnect 2 Air induction system hose air filter case air cut off valve 1 Remove from the air filter case side 3 Air cut off valve 1 4 Air induction system hose air cut off valve air induction system pipe 1 5 Air cut off valve bracket 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 5 3 4 ...

Page 253: ... off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hose Loose connections Connect properly Cracks damage Replace P...

Page 254: ...AIR INDUCTION SYSTEM 6 19 ...

Page 255: ...8 DIAGNOSTIC CODE TABLE 7 42 FUEL PUMP SYSTEM 7 47 CIRCUIT DIAGRAM 7 47 TROUBLESHOOTING 7 49 ELECTRICAL COMPONENTS 7 51 CHECKING THE SWITCHES 7 55 CHECKING THE BULBS AND BULB SOCKETS 7 58 CHECKING THE FUSES 7 59 CHECKING AND CHARGING THE BATTERY 7 60 CHECKING THE RELAYS 7 63 CHECKING THE TURN SIGNAL HAZARD RELAY 7 63 CHECKING THE DIODE 7 64 CHECKING THE SPARK PLUG CAP 7 65 CHECKING THE IGNITION CO...

Page 256: ...SOR 7 70 CHECKING THE THROTTLE POSITION SENSOR 7 70 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 7 71 CHECKING THE INTAKE AIR PRESSURE SENSOR 7 71 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 7 72 CHECKING THE FUEL INJECTOR 7 72 ...

Page 257: ......

Page 258: ...g Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B B B B B L B L B Y B Y O O O B O B Br Br B L B L B W B W B B G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb Br R B W Br B Y B B R B Y S...

Page 259: ...tch 5 Battery 6 Main fuse 7 Main switch 10 Ignition fuse 14 Right handlebar switch 16 Engine stop switch 19 Sidestand switch 20 Clutch switch 21 Diode 1 24 ECU engine control unit 25 Ignition coil 26 Spark plug 30 Lean angle sensor 35 Joint coupler 36 Frame ground ...

Page 260: ...s not flow to the ignition coil or in jector when the neutral switch circuit or sidestand switch circuit is open 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 switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down ...

Page 261: ... 4 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Diode 1 11 Neutral switch 12 Negative battery lead 13 Frame ground ...

Page 262: ...ttery OK 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 5 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 7 66 OK Ignition system is OK NG 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 7 65 NG Replace the spark plug cap OK 6 Check the ignition coil Refer to CHECKING THE IGNI TION CO...

Page 263: ...Replace the sidestand switch OK 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the clutch switch OK 13 Check the diode 1 Refer to CHECKING THE DIODE on page 7 64 NG Replace the diode 1 OK 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 67 NG Replace the lean angle sensor OK 15 Check the entire ignition system wiring Refer to CIRCU...

Page 264: ...B Y B Br W Br W Br R Br R Br R Br R R W Sb Sb Sb S b Sb G G G G G G R W B r Y Y Y Dg Dg Dg Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B L B Y B Y G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B Br WBr B Br R S...

Page 265: ...CHARGING SYSTEM 7 8 3 AC magneto 4 Rectifier regulator 5 Battery 6 Main fuse 36 Frame ground ...

Page 266: ...ING AND CHARGING THE BATTERY on page 7 60 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 7 68 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 68 NG Replace the rectifier regulator OK 5 Check the entire charging system wiring Refer to CIRC...

Page 267: ...CHARGING SYSTEM 7 10 ...

Page 268: ...g Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B B B B B L B L B Y B Y O O O B O B Br Br B L B L B W B W B B G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb Br R B W Br B Y B B R B Y S...

Page 269: ...2 Headlight fuse 24 ECU engine control unit 35 Joint coupler 36 Frame ground 39 Speedometer 42 Meter light 44 Tachometer 47 High beam indicator light 52 Headlight relay on off 53 Left handlebar switch 54 Pass switch 55 Dimmer switch 58 Tail brake light 63 Headlight 64 Auxiliary light ...

Page 270: ... CHECKING THE FUSES on page 7 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 7 55 NG The dimmer switch is faulty R...

Page 271: ...G SYSTEM 7 14 8 Check the entire lighting system wir ing Refer to CIRCUIT DIAGRAM on page 7 11 NG Properly connect or repair the lighting sys tem wiring OK Replace the ECU engine control unit or meter assembly ...

Page 272: ...Dg Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B B B B B L B L B Y B Y O O O B O B Br Br B L B L B W B W B B G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb Br R B W Br B Y B B R B Y ...

Page 273: ...sender 39 Speedometer 41 Speed sensor 43 Fuel level warning light 44 Tachometer 45 Neutral indicator light 46 Turn signal indicator light 48 Front brake light switch 49 Rear brake light switch 50 Turn signal hazard relay 51 Horn 53 Left handlebar switch 56 Horn switch 57 Turn signal switch 58 Tail brake light 59 Rear right turn signal light 60 Rear left turn signal light 61 Front right turn signal...

Page 274: ...ery Refer to CHECKING AND CHARGING THE BATTERY on page 7 60 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the main switch OK 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 15 NG Properly connect or repair or replace the signaling system wiring OK Check the condition of ...

Page 275: ... Replace the front brake light switch OK 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the rear brake light switch OK 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 15 NG Properly connect or repair or replace the signaling system wiring OK This circuit is OK 1 Check the turn signal indicator light bulb and socket Refer to ...

Page 276: ...ral indicator light bulb socket or both OK 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the neutral switch OK 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 15 NG Properly connect or repair the signaling system wiring OK Replace the meter assembly 1 Check the fuel level warning light bulb and socket Refer to CHECKING THE BULBS AND...

Page 277: ...SIGNALING SYSTEM 7 20 ...

Page 278: ...g Dg Dg Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B B B B B L B L B Y B Y O O O B O B Br Br B L B L B W B W B B G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb Br R B W Br B Y B B R...

Page 279: ...idestand switch 21 Diode 1 23 O2 sensor 24 ECU engine control unit 25 Ignition coil 26 Spark plug 27 Fuel injector 28 ISC idle speed control valve 29 FI diagnostic tool OPTION 30 Lean angle sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Intake air temperature sensor 34 Engine temperature sensor 35 Joint coupler 36 Frame ground 38 Air induction system solenoid 39 Speedometer 40...

Page 280: ...ine trouble warning light flashes while the engine is being cranked at an engine start up If a malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light After the engine has been stopped the lowest fault code number is i...

Page 281: ...gnal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions Warning light indication ECU operation Fuel injection operation Vehicle operation Flashing Warning provided when unable to start engin...

Page 282: ...n page 7 28 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine EAS30640 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators by connecting the FI diagnostic tool to the vehicle and setting it to the norma...

Page 283: ...LED orange comes on 5 Turn the main switch to OFF to cancel the normal mode 6 Disconnect the FI diagnostic tool and install the self diagnosis signal coupler cap Setting the diagnostic mode 1 Turn the main switch to OFF and engine stop switch to 2 Connect the self diagnosis signal coupler 1 to the FI diagnostic tool 2 as shown 3 Disconnect the wire harness coupler from the fuel pump 4 While pressi...

Page 284: ...ase the diagnostic code numbers 8 Check the operation of the sensor or actua tor Sensor operation The data representing the operating condi tions of the sensor appears on the LCD Actuator operation Set the engine stop switch to then to 9 Turn the main switch to OFF to cancel the diagnostic mode 10 Connect the fuel pump coupler 11 Disconnect the FI diagnostic tool and install the self diagnosis sig...

Page 285: ...to start engine Unable to drive vehicle Diagnostic code No FI diagnostic tool display Procedure Probable cause of malfunction Check or maintenance job 1 Installed condition of crankshaft position sensor Check for looseness or pinching 2 Connections Crankshaft position sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the co...

Page 286: ...ective intake air pressure sensor Execute diagnostic code No D03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 7 71 Reinstatement method Turn the main switch to ON Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D03 FI diagnostic tool disp...

Page 287: ...ub wire harness 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 securely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler L L blue blue B L B L black blue b...

Page 288: ...o start engine Unable to drive vehicle Diagnostic code No D20 FI diagnostic tool display Sidestand switch on sidestand retracted off sidestand extended Procedure Extend and retract the sidestand with the transmission in gear Probable cause of malfunction Check or maintenance job 1 Connections Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition...

Page 289: ...cking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor cou pler and ECU coupler Br W Br W brown white brown white B L B L black blue black blue 4 Defective intake air temperature sensor Execute diag...

Page 290: ...ve Reinstatement method Start the engine and let it run at idle or reset it with diagnostic code No D63 Fault code No 28 Item Engine temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D11 FI diagnostic tool display Displays the engine temperature Procedure Compare the actually measured engine temperature with the FI diag...

Page 291: ...6 4 5 upright 0 7 1 4 overturned Procedure Remove the lean angle sensor and incline it more than 45 degrees Probable cause of malfunction Check or maintenance job 1 The vehicle has overturned Raise the vehicle upright 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor 3 Connections Lean angle sensor coupler Wire harness ECU coupler Check the couple...

Page 292: ...tion repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open circuit Between ignition coil coupler and ECU cou pler O O orange orange 4 Defective ignition coil Execute diagnostic code No D30 Check the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COIL on page 7 ...

Page 293: ...ition posi tion when the engine is started This opera tion takes approximately 3 seconds until it is completed Start the engine If the error recurs replace the throttle body assembly Reinstatement method Turn the main switch to ON and back to OFF to return the ISC valve to its original position and then start the engine After starting let the engine run at idle speed for about 10 sec onds Fault co...

Page 294: ... Procedure Check that the number increases when the front wheel is rotated The number is cumulative and does not reset each time the wheel is stopped Probable cause of malfunction Check or maintenance job 1 Connections Speed sensor coupler 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 295: ...five times by listening for the operating sound Probable cause of malfunction Check or maintenance job 1 Connections Fuel pump relay coupler Fuel pump coupler Injector coupler 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 securely 2 Open or short circuit in wire h...

Page 296: ...efer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 7 Replace the ECU if defective Reinstatement method Turn the main switch to ON Fault code No 46 Item Power supply to the fuel injection system is not normal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI diagnostic tool display Procedure Probable cause of malfunction Check or maintenance job 1 Connections Wire ha...

Page 297: ...nds Fault code No 50 Item Malfunction in ECU memory Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No FI diagnostic tool display Procedure Probable cause of malfunction Check or maintenance job 1 Malfunction in ECU Replace the ECU TIP Do not replace the ECU with the main switch set to ON Reinstatement method Turn the main switch to ON Fault code No 70 Item Engine i...

Page 298: ...FUEL INJECTION SYSTEM 7 41 1 Reinstatement method Fault code No 70 Item Engine idling stop engine has been left idling The ECU automatically stops the engine after 20 minutes if it is left idling ...

Page 299: ...peed pulse 0 999 Check that the number increases when the front wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped D08 Lean angle sensor Remove the lean angle sensor and incline it more than 45 degrees Upright 3 4 4 5 Overturned 0 7 1 4 D09 Fuel system voltage battery voltage Approximately 12 0 Compare the actually mea sured battery voltage with the FI dia...

Page 300: ...WARNING LED on the FI diagnostic tool comes on each time the solenoid is actuated Check that the air induction system solenoid is actu ated five times by listening for the operating sound D50 Fuel pump relay When the engine stop switch is set from to the fuel pump relay is actuated five times at five second intervals 2 seconds ON 3 seconds OFF and the WARNING LED on the FI diagnostic tool comes on...

Page 301: ...ng value is detected D61 Malfunction history code display No history 00 History exists 12 70 Fault code number If more than one malfunc tion is detected the dis play switches every two seconds to show the fault code numbers of all mal functions in a repeating cycle D62 Malfunction history code erasure No history 00 History exists Displays the total number of malfunctions including the current malf...

Page 302: ... lead is not connected properly Main switch is in the position Malfunction in wire harness ECU coupler Malfunction in FI diagnostic tool coupler Open or short circuit in wire harness Malfunction in FI diagnostic tool Malfunction in ECU ERROR_4 Commands from the FI diagnostic tool are not accepted by the ECU Vehicle battery is insufficiently charged Malfunction in wire harness ECU coupler Malfuncti...

Page 303: ...FUEL INJECTION SYSTEM 7 46 ...

Page 304: ...Dg Dg Dg Dg Dg Dg Ch Ch Ch Ch Ch Ch Ch Ch B B B B B B B B B B B B B B B B B B B B B B B B B B L B L B Y B Y O O O B O B Br Br B L B L B W B W B B G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B B r B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb Br R B W Br B Y B B R B Y ...

Page 305: ... 5 Battery 6 Main fuse 7 Main switch 9 Fuel injection system fuse 10 Ignition fuse 14 Right handlebar switch 16 Engine stop switch 17 Fuel pump relay 22 Fuel pump 24 ECU engine control unit 35 Joint coupler 36 Frame ground ...

Page 306: ...ls Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the main switch OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 55 NG Replace the right handlebar switch OK 5 Check the fuel pump relay Refer to CHECKING THE RE LAYS on page 7 63 NG Replace the fuel pump relay OK 6 Check the fuel pump Refer to CHECKING THE...

Page 307: ...FUEL PUMP SYSTEM 7 50 ...

Page 308: ...ELECTRICAL COMPONENTS 7 51 EAS27973 ELECTRICAL COMPONENTS 11 9 12 13 14 15 1 2 3 4 5 6 7 8 10 ...

Page 309: ...in switch 2 Front brake light switch 3 Clutch switch 4 Ignition coil 5 Fuel sender 6 Battery 7 Main fuse 8 Fuse box 9 Diode 1 10 Diode 2 11 Neutral switch 12 Rectifier regulator 13 Sidestand switch 14 Rear brake light switch 15 Horn ...

Page 310: ...ELECTRICAL COMPONENTS 7 53 14 2 15 1 3 4 5 6 7 8 10 11 13 12 9 ...

Page 311: ... speed control valve 4 Fuel injector 5 Throttle position sensor 6 ECU engine control unit 7 Headlight relay on off 8 Fuel pump relay 9 Turn signal hazard relay 10 Lean angle sensor 11 Fuel pump 12 Intake air temperature sensor 13 Stator coil assembly 14 Air induction system solenoid 15 O2 sensor ...

Page 312: ...ELECTRICAL COMPONENTS 7 55 EAS27981 CHECKING THE SWITCHES 12 10 8 7 6 1 P B R Y Y L B Y G Ch Br W Dg R B R W Ch Br W Dg RUN 2 3 4 5 9 11 R L B Br R L Y Br L ...

Page 313: ...56 1 Clutch switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Sidestand switch 7 Neutral switch 8 Main switch 9 Front brake light switch 10 Hazard switch 11 Engine stop switch 12 Rear brake light switch ...

Page 314: ...r continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by The...

Page 315: ... WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transp...

Page 316: ...nuity TIP Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating oth...

Page 317: ...eaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batter...

Page 318: ...e negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not ...

Page 319: ...rs If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ...

Page 320: ...wn Check the relay operation Out of specification Replace Fuel pump relay Headlight relay on off EAS2RD1023 CHECKING THE TURN SIGNAL HAZARD RELAY 1 Check Turn signal hazard relay input voltage Out of specification The wiring circuit from the main switch to the turn signal hazard re lay coupler is faulty and must be repaired Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog p...

Page 321: ...upler as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage EAS28050 CHECKING THE DIODE 1 Check Diode Out of specification Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown red 1 Negative tester probe Ground Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Posi...

Page 322: ...ecification Replace a Disconnect the ignition coil lead terminals from the wire harness Continuity Positive tester probe sky blue 1 Negative tester probe black red 2 Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 3 No continuity Positive tester probe black red 2 Negative tester probe sky blue 1 No continuity Positive tester probe black yellow 3 Negative tester probe...

Page 323: ...HOOTING on page 7 5 a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Turn the main switch to ON d Measure the ignition spark gap a e Crank the engine and gradually increase the spark plug gap until a misfire occurs Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe orange 1 Negative tester probe red white 2 Secondary coil ...

Page 324: ...gle sensor 2 and wire harness 3 as shown b Connect the pocket tester DC 20 V to the test harness as shown c Turn the main switch to ON d Turn the lean angle sensor to 45 e Measure the lean angle sensor output volt age Crankshaft position sensor resis tance 192 288 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe blue yellow 1 Negative tester probe green white 2 1 2 L...

Page 325: ...o the spark plug lead b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it warm up d Measure the rectifier regulator output volt age EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace Stator coil resistance 0 184 0 276 W W Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Neg...

Page 326: ...ket tester 100 to the en gine temperature sensor terminal as shown b Immerse the engine temperature sensor 1 in a container 2 filled with water TIP Make sure that the engine temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the spec ified temperatures e Measure the engine temperature sensor re sistance 3 Install Engine temperat...

Page 327: ...of the front wheel the voltage reading should cycle from 0 V 5 V 0 V 5 V 3 Install Headlight unit assembly Refer to STEERING HEAD on page 4 44 EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester 1k to the throt...

Page 328: ...ING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sensor 3P 1 to the intake air pressure sensor 2 and wire harness 3 b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe blue 1 Negative tes...

Page 329: ...nals 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 intake air temperature sensor resistance 3 Install Intake air temperature sensor Refer to GENERAL CHASSIS on page 4 1 EAS2RD1042 CHECKING THE FUEL INJECTOR 1 Remove Fuel injector Refer to THROTTLE BODY on page 6 9 2 Check Fuel injector resistance Out of ...

Page 330: ...ELECTRICAL COMPONENTS 7 73 c Measure the fuel injector resistance Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 ...

Page 331: ...CORRECT ENGINE 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 2 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 332: ...logged or damaged fuel hose 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or d...

Page 333: ...50 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Inc...

Page 334: ... improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube 4 ...

Page 335: ... Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Disconnected or damaged wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal haza...

Page 336: ...TROUBLESHOOTING 8 5 ...

Page 337: ...43 Fuel level warning light 44 Tachometer 45 Neutral indicator light 46 Turn signal indicator light 47 High beam indicator light 48 Front brake light switch 49 Rear brake light switch 50 Turn signal hazard relay 51 Horn 52 Headlight relay on off 53 Left handlebar switch 54 Pass switch 55 Dimmer switch 56 Horn switch 57 Turn signal switch 58 Tail brake light 59 Rear right turn signal light 60 Rear ...

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Page 341: ...G G Br R L L Br R Br R B B B B B B B B B R R L B L B L Y L Y R R Br L Br L R W R W R W R W R B R B Y Y Y Y B B L R L R R W R W B B W W W W G Y G Y G Y G Y Br B Br B Br R L Y R R L Y B B B B B B B B B B B B B B Br WBr B Br R Sb B Br W Br B Sb Br R B W Br B Y B B R B Y Sb B R B R R1 R1 R B B B R Br W Br R R Br R L B R R Dg R B Br W Br R Ch R W Br L L B L Y B B B B B W B B B B B B L B L B L B L B L B...

Page 342: ...18 J01 J07 RUN OFF OFF ON 7 5A 7 5A 10A 15A 7 5A 15A 30A J08 ON P OFF LOCK J09 J19 J17 H20 H21 1 7W 1 7W 1 7W J16 1 7W 1 7W 1 7W 1 7W B SR400 SR400E 2014 WIRING DIAGRAM SR400 SR400E 2014 SCHÉMA DE CÂBLAGE SR400 SR400E 2014 SCHALTPLAN SR400 SR400E 2014 SCHEMA ELETTRICO SR400 SR400E 2014 DIAGRAMA ELÉCTRICO 2RD 28197 E0_400 297_W D indd 2 2013 11 26 14 21 41 ...

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