Yamaha Star XVS950A 2009 Service Manual Download Page 173

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FRONT FORK

4-52

TIP

Adjust the oil seal clip so that it fits into the
outer tube’s groove.

9. Install:

• Dust seal “1”

(with the fork seal driver weight “2”)

10. Fill:

• Front fork leg

(with the specified amount of the recom-
mended fork oil)

11. Measure:

• Front fork leg oil level “a”

(from the top of the inner tube, with the
outer tube fully compressed and without
the fork spring)
Out of specification

→

Correct.

TIP

• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up

and down to distribute the fork oil.

12. Install:

• Spring
• Spring seat
• Spacer
• Cap bolt

(along with the O-ring

)

TIP

• Before installing the cap bolt, lubricate its O-

ring with grease.

• Temporarily tighten the cap bolt.
• Tighten the cap bolt specified torque, when

installing the front fork with upper bracket.

EAS23050

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Install:

• Lower front fork cover “1”
• Front fork leg “2”
• Upper bracket “3”

Temporarily tighten the upper and lower
bracket pinch bolts.

TIP

Make sure the inner tube end is flush with the
top of the upper bracket.

Fork seal driver

90890-01442

Adjustable fork seal driver (36–
46 mm)

YM-01442

Quantity

488.0 cm

(16.50 US oz, 17.21

Imp oz)

Recommended oil

Yamaha fork oil 10WT

Level

107.0 mm (4.21 in)

New

Summary of Contents for Star XVS950A 2009

Page 1: ...SERVICE MANUAL XVS950A Y 2009 26P 28197 E0 ...

Page 2: ...S950A Y SERVICE MANUAL 2008 by Yamaha Motor Co Ltd First edition November 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...ignificant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers 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 symbo...

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

Page 5: ...N SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOC TITE Engine oil Replace the part with a new one ...

Page 6: ......

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

Page 8: ......

Page 9: ... OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 10: ...140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 2 3 1 1 ...

Page 11: ...e 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 man ner To accommodate 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 times...

Page 12: ...d by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor lean angle 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 that is r...

Page 13: ...key to ON before using the SELECT switch and RESET switch except for setting the brightness control mode Speedometer The speedometer shows the riding speed When the key is turned to ON the speedom eter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit Clock To set the clock 1 Push the SELECT switch and the RESET switch together for at lea...

Page 14: ...ctrical circuits If any of those circuits are defective the engine trouble warning light will come on and then the odometer tripmeter clock display will indicate a two digit error code e g 12 13 14 This model is also equipped with a self diagno sis device for the immobilizer system If any of the immobilizer system circuits are defective the immobilizer system indicator light will flash and then th...

Page 15: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals a...

Page 16: ...ed grease Oil bearings liberally when installing if appro priate ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposi...

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

Page 18: ...ow to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 8 7 89 7 90 7 91 7 95 7 96 7 97 7 98 7 99 7 100 7 101 7 102 7 103 7 104 7 105 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 7 Vacuum gauge ...

Page 19: ...rive belt tension gauge YM 03170 3 19 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 21 4 56 Damper rod holder 90890 01460 4 49 4 51 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 49 4 51 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 51 4 52 Tool name Tool No Illustration Reference pages ...

Page 20: ... 6 mm YU 01083 1 5 15 Weight 90890 01084 YU 01083 3 5 15 Valve spring compressor 90890 04019 YM 04019 5 26 5 31 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 26 5 31 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 28 Tool name Tool No Illustration Reference pages YU 01083 3 ...

Page 21: ...mer 6 0 mm YM 04066 5 28 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 34 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 42 5 43 5 49 5 51 Flywheel puller set 90890 01468 Heavy duty puller YU 33270 B 5 42 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 43 5 64 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 22: ...9 6 11 Fuel pressure adapter 90890 03176 YM 03176 6 11 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 58 6 11 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 98 Digital tachometer 90890 06760 YU 39951 B 3 5 3 9 Tool name Tool No Illustration Reference pages ...

Page 23: ...11 TIGHTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 CABLE ROUTING 2 35 ...

Page 24: ...1 27B2 AUS Dimensions Overall length 2435 mm 95 9 in Overall width 1000 mm 39 4 in Overall height 1080 mm 42 5 in Seat height 675 mm 26 6 in Wheelbase 1685 mm 66 3 in Ground clearance 145 mm 5 71 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel 278 kg 613 lb Maximum load 210 kg 463 lb ...

Page 25: ...AMALUBE 4 10W 40 or 20W 50 SAE 10W 40 or SAE 20W 50 AUS Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 4 30 L 4 55 US qt 3 78 Imp qt Without oil filter cartridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil filter Oil filter type Wire mesh Oil pump Oil pump type Trocho...

Page 26: ...B 37 015 37 115 mm 1 4573 1 4612 in Limit 36 915 mm 1 4533 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Rocker arm shaft outside diameter 11 981 11 991 mm 0 4717 0 4721 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in Limit 0 095 mm 0 0037 in V...

Page 27: ... clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Valve guide position 12 7 13 1 mm 0 500 0 515 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve spring Free length intake 42 43 mm 1 67 in Limit 40 3...

Page 28: ...31 in Offset 0 50 mm 0 0197 in Piston pin bore inside diameter 21 004 21 015 mm 0 8269 0 8274 in Limit 21 045 mm 0 8285 in Piston pin outside diameter 20 991 21 000 mm 0 8264 0 8268 in Limit 20 971 mm 0 8256 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Piston ring Top ring Ring type Barrel Dimensions B T 1 20 2 90 mm 0 05 0 11 in End gap installed 0 15 0 30 mm 0 005...

Page 29: ...side diameter 50 010 50 030 mm 1 9689 1 9697 in Crankshaft journal to crankshaft journal bear ing clearance 0 030 0 062 mm 0 0012 0 0024 in Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Operation Left hand operation Clutch lever free play 5 0 10 0 mm 0 20 0 39 in Friction plate 1 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate q...

Page 30: ...ent Fuel pump Pump type Electrical Maximum consumption amperage 5 5 A Fuel pressure 392 0 kPa 3 92 kgf cm2 56 9 psi Fuel injector Model quantity 1450 2 Throttle body Type quantity ACW35 1 ID mark 5S71 00 Throttle valve size 100 Throttle position sensor Resistance 3 08 5 72 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω Intake air pressur...

Page 31: ... Wear limit front 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Rear tire Type Tubeless Size 170 70B 16M C 75H Manufacturer model BRIDGESTONE EXEDRA G722 J Manufacturer model DUNLOP K555 Wear limit rear 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Loading condition ...

Page 32: ...ring bearing type Angular bearing Center to lock angle left 35 0 Center to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 135 0 mm 5 31 in Fork spring free length 366 mm 14 41 in Limit 359 mm 14 13 in Spacer length 183 0 mm 7 20 in Installed length 339 4 mm 13 36 in Spring rate K1 5 41 N mm 0 55 kgf mm 30 90 lbf in Sp...

Page 33: ...ee play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive belt Model manufacturer MD01 MITSUBOSHI Drive belt slack on the sidestand 3 0 5 0 mm 0 12 0 20 in Drive belt slack on a suitable stand 3 0 5 0 mm 0 12 0 20 in Shift pedal Installed shift rod length 278 7 280 7 mm 10 97 11 05 in ...

Page 34: ...e than 45 3 7 4 4 V AC magneto Standard output 14 0 V 32 9 A at 5000 r min Standard output 14 0 V 460 W at 5000 r min Stator coil resistance 0 128 0 192 Ω Rectifier regulator Regulator type Semiconductor short circuit Charging voltage 14 V at 5000 r min Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model YTZ14S Specific gravity 1 31 Voltage capacity...

Page 35: ...depth 0 70 mm 0 03 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Coil resistance 1 07 1 11 Ω Performance 108 116 dB 2 m Turn signal hazard relay Relay type Semi transistor Built in self canceling device Yes Turn signal relay input voltage DC 12 V Turn signal relay output voltage DC 12 V Turn signal blinking frequency 75 0 95...

Page 36: ...le 0 6 V to 4 8 V to 0 6 V to 4 8 V Fuses Main fuse 40 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Fuel injection system fuse 10 0 A Backup fuse 10 0 A Parking lighting fuse 10 0 A Reserve fuse 20 0 A Reserve fuse 15 0 A Reserve fuse 10 0 A ...

Page 37: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents 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 38: ...ocknut rocker arm adjusting screw M8 8 27 Nm 2 7 m kgf 19 ft lbf Timing chain guide stopper bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Camshaft sprocket bolt M10 2 55 Nm 5 5 m kgf 40 ft lbf Timing chain tensioner cap bolt M11 2 24 Nm 2 4 m kgf 17 ft lbf Oil pump assembly bolt M8 3 24 Nm 2 4 m kgf 17 ft lbf Oil filter cartridge M20 1 17 Nm 1 7 m kgf 12 ft lbf Oil filter cartridge union bolt M20 1 30 Nm 3...

Page 39: ...35 ft lbf Stator coil bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft position sensor bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Oil baffle plate 1 bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Oil baffle plate 2 bolt M6 5 10 Nm 1 0 m kgf 7 2 ft lbf Primary drive gear bearing plate bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Drive pulley cover bolt M6 5 8 Nm 0 8 m kgf 5 8 ft lbf Primary drive gear plastic cover 1 bolt ...

Page 40: ...Nm 2 5 m kgf 18 ft lbf 4 Follow the tightening direction and tighten to 65 Nm 6 5 m kgf 47 ft lbf Front cylinder head Rear cylinder head TIP Connecting rod bolt Tighten the connecting rod bolts to 15 Nm 1 5 m kgf 11 ft lbf and then tighten them further to reach the specified angle 125 135 Speed sensor bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Speed sensor lead bracket screw M6 1 7 Nm 0 7 m kgf ...

Page 41: ...regulator bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft lbf Rectifier regulator bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Throttle cable guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear shock absorber assembly lower nut M10 1 48 Nm 4 8 m kgf 35 ft lbf Rear shock absorber assembly upper nut M10 1 48 Nm ...

Page 42: ...Rear wheel drive hub stud bolt M12 5 30 Nm 3 0 m kgf 22 ft lbf Upper bracket pinch bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Steering stem nut M22 1 110 Nm 11 m kgf 80 ft lbf Lower ring nut initial tightening torque M25 1 52 Nm 5 2 m kgf 37 ft lbf See TIP Lower ring nut final tightening torque M25 1 18 Nm 1 8 m kgf 13 ft lbf See TIP Lower bracket pinch bolt M8 4 45 Nm 4 5 m kgf 32 ft lbf Lower front for...

Page 43: ...attery lead bolt starter relay side M6 1 4 Nm 0 4 m kgf 2 9 ft lbf Starter motor lead bolt starter relay side M6 1 4 Nm 0 4 m kgf 2 9 ft lbf Battery box bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Lean angle sensor bracket bolt M4 2 2 Nm 0 2 m kgf 1 4 ft lbf Sidestand bracket bolt M10 2 56 Nm 5 6 m kgf 40 ft lbf Sidestand switch bolt M5 2 4 Nm 0 4 m kgf 2 9 ft lbf Sidestand nut M10 1 64 Nm 6 4 m kgf 46 ft...

Page 44: ...bolt TIP Lower ring nut 1 First tighten the lower ring nut to approximately 52 Nm 5 2 m kgf 37 ft lbf with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 18 Nm 1 8 m kgf 13 ft lbf with a torque wrench TIP Upper handlebar holder bolt First tighten the bolts on the front side of the upper handlebar holder and then on the rear side TIP Front brake master c...

Page 45: ...e gear 1 shaft Starter clutch idle gear 1 Starter clutch gear inner and outer surfaces Starter clutch and metal to metal moving parts Starter clutch idle gear 2 Primary driven gear inner surface Clutch pull rod Oil pump drive sprocket inner surface Clutch thrust washers Clutch boss nut and washer Transmission gears wheel and pinion and collar Shift forks and shift fork guide bars Shift drum Shift ...

Page 46: ...r surface and throttle cables Brake lever pivoting point and metal to metal moving parts Brake master cylinder push rod contact surface Clutch lever pivoting point and metal to metal moving parts Swingarm pivot bearings inner surface Swingarm pivot oil seals lip Rear shock absorber assembly upper bolt Connecting arm and swingarm collar outer surface Relay arm bearings inner surface Relay arm oil s...

Page 47: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 48: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 49: ... strainer 2 Oil pump assembly 3 Oil delivery pipe 2 4 Relief valve assembly 5 Drive axle 6 Oil filter cartridge 7 Main axle 8 Main gallery 9 Crankshaft 10 Clutch cover 11 Valve stem end intake side 12 Rear cylinder camshaft 13 Front cylinder camshaft ...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil filter cartridge 2 Oil delivery pipe 2 3 Relief valve assembly ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Crankshaft ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil drain bolt 2 Crankshaft ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Drive axle 2 Oil delivery pipe 1 3 Main axle 4 Oil delivery pipe 2 5 Oil pump assembly 6 Oil strainer ...

Page 58: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING ...

Page 59: ...icle C Insert the rear brake light switch coupler into the rectifier regulator bracket com pletely D Clamp the starter motor lead horn lead and rear brake light switch lead Opening can face any direction E The lower end of the mark gray on the starter motor lead should be above the lower end of the clamp F Clamp the AC magneto lead and rectifier regulator lead Face the ends of the hose clamp up G ...

Page 60: ...CABLE ROUTING 2 37 ...

Page 61: ...ar switch lead B Route the intake air temperature sensor lead above the main switch lead and left handlebar switch lead C Route the left handlebar switch lead D Clamp the handlebar switch lead at the positioning tape E Route the right handlebar switch lead and front turn signal light lead F Clamp inside the positioning taped area G Route the right handlebar switch lead front turn signal light lead...

Page 62: ...CABLE ROUTING 2 39 ...

Page 63: ...the bracket behind the branched section of the throttle position sensor lead F Route the throttle position sensor lead out side of the intake air pressure sensor air hose G Branch to throttle position sensor H Put the marking of the throttle cable return side between the tabs of throttle body I Branch to intake air pressure sensor J Route the intake air pressure sensor lead outside of the hose K M...

Page 64: ...CABLE ROUTING 2 41 ...

Page 65: ... the bracket Face the end inside D Route the rear right turn signal light lead and starter motor lead outside of the guide wire E Clamp the O2 sensor lead Face the open ing outside F Clamp the starter motor lead to the bracket with the sheet dropping key rotor Face the lock inside and down Cut off the excess end G Clamp the joint coupler lead and starter motor lead H Face the lock of the clamp tow...

Page 66: ...CABLE ROUTING 2 43 ...

Page 67: ...brake hose with its paint mark facing up G Install the rear brake hose onto the rear brake caliper making sure that the brake pipe touches the projection on the caliper H Make sure to insert the clamp I Install the rear brake hose onto the rear brake master cylinder making sure that the brake pipe touches the projection on the rear brake master cylinder bracket J 90 K Install the clamp under the r...

Page 68: ...CABLE ROUTING 2 45 ...

Page 69: ... lead and horn lead Face the lock down and cut off the excess end H Clamp the starter motor lead rectifier reg ulator lead rear brake switch lead and horn lead to the engine mount boss Face the lock to the front and cut off the excess end Make sure to fasten the band to the engine boss I Clamp the starter motor lead rear brake switch lead horn lead and fuel tank breather hose Face the ends of the ...

Page 70: ...CABLE ROUTING 2 47 ...

Page 71: ...d rectifier regulator lead rear brake switch lead and horn lead with the speed sensor lead bracket I Clamp the starter motor lead Face the clamp s opening to outside J Pass them inside the cable guide K Route inside of the engine bracket L Clamp the starter motor lead sidestand switch lead AC magneto lead oil level switch lead rectifier regulator lead rear brake switch lead and horn lead to the br...

Page 72: ...CABLE ROUTING 2 49 ...

Page 73: ...h the opening facing up C Clamp the crankcase breather hose and high tension code D Make sure to insert the wire harness clamp to the frame hole E To tail brake light assembly F Clamp the wire harness meter lead and battery negative lead Face the end to the front G Make sure that a nail can be hooked in the seat lock bracket hole and insert until firmly fixed H Make sure that a nail can be hooked ...

Page 74: ...CABLE ROUTING 2 51 ...

Page 75: ...der lead to the front B Install the clip by adjusting its knob to the mark C Face the ends of the hose clamp upward D Face the clip s knob to the right E Face the clip s knob to the back F Face the clip s knob to the left G After routing the meter lead bend the clamp and fasten H Press the hose against the spool Soap suds can be applied when installing I Face the ends of the hose clamp outward ...

Page 76: ...CABLE ROUTING 2 53 ...

Page 77: ...hang the tail brake light wire harness on the mudguard s hook C Route the tail brake light wire harness rear turn signal lead license plate light lead through each clamp Make sure that no leads come out of the clamp after bending it D The slit can face any direction E Silicon fluid or soapsuds can be applied when installing F Route the license plate light lead above the clamp coupler G Route the r...

Page 78: ...CABLE ROUTING 2 55 ...

Page 79: ...der lead above the spark plug lead H When clamping the branch section of the engine temperature sensor lead put it inside of the clamp I To the fuel tank J Spark plug and wire harness K Install with the opening facing back L To the rear cylinder M Route the ISC Idle Speed Control lead inside of the spark plug lead N To the front cylinder O To the wire harness P To the ISC idle speed control valve ...

Page 80: ...CABLE ROUTING 2 57 ...

Page 81: ...nd install B Route the intake air pressure hose inside of the frame bracket C Face the white paint mark to the right and install D Projection from the clip of the intake air pressure hose 2 locations E Install the side of the intake air pressure hose to the side of the throttle body boss Engine oil can be applied when installing ...

Page 82: ...CABLE ROUTING 2 59 ...

Page 83: ... the knob to the front F Yellow paint position G Install by adjusting to the yellow paint mark H Insert until contacting the air filter case insert 15 mm I Adjust to the Crankcase breather hose paint and then adjust the knob to the back J Route the crankcase breather hose above the fuel tank bracket adjust the paint to the 6S5 on the hose joint and then install K Clamp the frame and Crankcase brea...

Page 84: ...CABLE ROUTING 2 61 ...

Page 85: ...HE HYDRAULIC BRAKE SYSTEM 3 15 CHECKING THE FRONT BRAKE HOSE 3 16 CHECKING THE REAR BRAKE HOSES 3 17 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 3 19 ADJUSTING THE DRIVE BELT SLACK 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 20 LUBRICATING THE STEERING BEARINGS 3 21 CHECKING THE CHASSIS FASTENERS 3 21 LUBRICATING ...

Page 86: ...TING THE THROTTLE CABLE FREE PLAY 3 28 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE 3 29 CHECKING AND CHARGING THE BATTERY 3 29 CHECKING THE FUSES 3 29 CHECKING THE SWITCHES 3 29 ADJUSTING THE HEADLIGHT BEAM 3 29 REPLACING THE HEADLIGHT BULB 3 29 ...

Page 87: ......

Page 88: ... special tools data and technical skills have a Yamaha dealer perform the service No ITEM ROUTINE INITIAL ODOMETER READINGS 1000 km 600 mi or 1 month 7000 km 4000 mi or 6 months 13000 km 8000 mi or 12 months 19000 km 12000 mi or 18 months 25000 km 16000 mi or 24 months 31000 km 20000 mi or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check conditio...

Page 89: ... air pressure Correct if necessary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check bearing assemblies for looseness 10 Drive belt Check belt tension Adjust if necessary Every 4000 km 2500 mi 11 Steering bearings Check bearing assemblies for looseness Moderately repack with lith ium soap based grease Every 19000 km 12000 mi 12 Chassis fasten...

Page 90: ...years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 21 Rear suspension link pivots Apply lithium soap based grease lightly 22 Engine oil Change warm engine before draining 23 Engine oil filter cartridge Replace 24 Front and rear brake switches Check operation 25 Control cables...

Page 91: ...rk plugs 1 Remove Rear cylinder right plastic cover Refer to ENGINE REMOVAL on page 5 1 2 Disconnect Spark plug cap 3 Remove Spark plug ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode Damage wear Replace the spark plug Insulato...

Page 92: ...or cover is within the firing range b on the generator rotor Incorrect firing range Check the ignition system TIP The ignition timing is not adjustable 4 Install Timing mark accessing screw along with the O ring Generator cover damper Damper cover EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engi...

Page 93: ...ATOR AND STARTER CLUTCH on page 5 39 5 Remove Front cylinder tappet covers 1 6 Remove Rear cylinder tappet covers 1 7 Measure Valve clearance Out of specification Adjust Front cylinder a Turn the crankshaft counterclockwise b When the front cylinder piston is at TDC on the compression stroke align the TDC mark a on the generator rotor with the slot b in the generator cover TIP When the piston is a...

Page 94: ...cknuts 1 b Insert a thickness gauge 2 between the end of the adjusting screw 3 and the valve tip c Turn the adjusting screw in direction a or b with the hexagon wrench 4 until the specified valve clearance is obtained d Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion e Measure the valve clearance again f If the valve clearance is still out of specifi ca...

Page 95: ...the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 6 1 Drive pulley cover Air duct Refer to BELT DRIVE on page 4 65 Air filter case Side cover cylinder head Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20570 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filte...

Page 96: ...ond and check the synchronization again If a bypass air screw was removed clean or replace the throttle bodies ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization b Check the vacuum pressure If out of specification Adjust the throttle body synchronization 8 Stop the engine and remove the measuring equipment Vacuum gauge 90890 03094 Carburetor synchr...

Page 97: ...o set the CO density level to stan dard and then adjust the exhaust gas volume 1 Turn the main switch to OFF 2 Simultaneously press and hold the SELECT and RESET switches turn the main switch to ON and continue to press the switches for 8 seconds or more TIP All displays on the meter disappear except the odometer trip meter fuel reserve trip meter clock display dIAG appears on the odometer trip me...

Page 98: ...ute the selection 7 Change the CO adjustment volume by pressing the SELECT and RESET switches TIP The CO adjustment volume appears on the odometer trip meter fuel reserve trip meter clock LCD To decrease the CO adjustment volume press the RESET switch To increase the CO adjustment volume press the SELECT switch 8 Release the switch to execute the selec tion 9 Simultaneously press the SELECT and RE...

Page 99: ... the engine b Grab the clutch lever and make sure that you can shift the gear smoothly c Grab the clutch lever and shift to first gear d Operate both the front and rear brakes release the clutch lever slowly and make sure that the engine stops EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Handlebar side a ...

Page 100: ...Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake master cylinder reser voir and brake fluid reservoir Water will si...

Page 101: ...he brake lever free play make sure there is no brake drag EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 19 EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal adjusting bolt position Adjust ...

Page 102: ...E on page 4 31 EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS TEM WARNING EWA13100 Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding th...

Page 103: ...to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEV...

Page 104: ...over lower Refer to SWINGARM on page 4 62 Muffler Refer to ENGINE REMOVAL on page 5 1 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 replaced always balance the wheel EAS21650 CHECKING THE TIRES The following pro...

Page 105: ...ormal 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 direction of wheel rotation Align the mark 2 with the valve installation point Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Loading condition 90 210 kg 198 ...

Page 106: ...ithin the speci fied limits TIP Measure the drive belt slack when the engine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the sidestand or on a suit able stand so that the rear wheel is elevated 2 Check Drive belt slack a Out of specification Adjust ...

Page 107: ...ecifi cation 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 EAS21510 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently ...

Page 108: ... nut with their sharp edged sides a facing each other g Finger tighten the upper ring nut 2 and then align the slots of both ring nuts If nec essary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs b sit correctly in the ring nut slots c 5 Install Upper bracket Refer to FRONT FORK on page 4 46 EAS5S7...

Page 109: ...h is within specification EAS3D84002 LUBRICATING THE SHIFT PEDAL Lubricate the pivoting point and metal to metal moving parts of the shift pedal EAS5S71034 CHECKING THE SIDESTAND 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the sidestand is elevated 2 Check Sidest...

Page 110: ...check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 46 EAS5S71025 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Damper rod Oil leakage Gas leakage Spring Refer to CHECKING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 60 2 Check Operation Pump the rear shock absorber assembly up and down several times Unsmooth operation Replace rear shock absorber assembl...

Page 111: ...ilt to the side can result in a false read ing 2 Start the engine warm it up for several minutes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maxi mum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled D...

Page 112: ...hen turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS20780 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several minutes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Dipstick 1 along with the O ring Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil ...

Page 113: ... level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 24 12 Remove Side cover cylinder head Refer to GENERAL CHASSIS on page 4 1 Rear cylinder right plastic cover Rear cylinder right plastic cover bracket Refer to ENGINE REMOVAL on page 5 1 Fuel tank bracket bolts Refer to FUEL TANK on page 6 1 13 Check Engine oil pressure a Slightly loosen the front cylinder oil check bolt 1 and rear cylinder o...

Page 114: ...E LIGHT SWITCH TIP The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn t...

Page 115: ...ttle body syn chronization should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Remove Rider seat Side cover cylinder head Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 3 Adjust Throttle cable free play Throttle body side a Loosen the locknut 1 on the accelerator cable b Turn the adjusting nut 2 in direction a or b until the s...

Page 116: ...to ELECTRICAL COMPONENTS on page 7 83 EAS21810 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw with a screw driver in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw with a screw driver in direction a or b EAS21790 REPLACING THE HEADLIGHT BULB 1 Remove Turn signal light bracket cover 1 Direction a Throttle cable free play ...

Page 117: ...eadlight bulb Secure the new headlight bulb with the headlight bulb holder ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 8 Attach Headlight ...

Page 118: ...PERIODIC MAINTENANCE 3 31 ...

Page 119: ... REPLACING THE FRONT BRAKE PADS 4 25 REMOVING THE FRONT BRAKE CALIPER 4 26 DISASSEMBLING THE FRONT BRAKE CALIPER 4 26 CHECKING THE FRONT BRAKE CALIPERS 4 26 ASSEMBLING THE FRONT BRAKE CALIPER 4 27 INSTALLING THE FRONT BRAKE CALIPER 4 27 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 29 INSTALLING THE FRONT BR...

Page 120: ... THE STEERING HEAD 4 56 REAR SHOCK ABSORBER ASSEMBLY 4 58 HANDLING THE REAR SHOCK ABSORBER 4 59 DISPOSING OF A REAR SHOCK ABSORBER 4 59 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 59 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 60 CHECKING THE CONNECTING ARM AND RELAY ARM 4 60 INSTALLING THE RELAY ARM 4 60 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 60 SWINGARM 4 62 REMOVING THE SWINGARM 4 63 CHE...

Page 121: ......

Page 122: ...arts to remove Q ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Right side cover 1 4 Left side cover 1 5 Seat lock cable assembly 1 Disconnect 6 Key cylinder seat lock 1 7 Meter coupler 1 Disconnect 8 Seat lock bracket 1 9 Side cover cylinder head 1 For installation reverse the removal proce dure ...

Page 123: ...s to remove Q ty Remarks 1 Turn signal light bracket cover 1 2 Headlight lens unit 1 3 Headlight coupler 1 Disconnect 4 Turn signal light coupler 2 Disconnect 5 Wire harness clamp 3 Disconnect 6 Headlight body 1 For installation reverse the removal proce dure ...

Page 124: ... Battery 1 6 ECU coupler 2 Disconnect 7 ECU engine control unit 1 8 Starter relay coupler 1 Disconnect 9 Starter relay cover 1 10 Starter motor lead 1 Disconnect 11 Positive battery lead starter relay 1 Disconnect 12 Starter relay 1 13 Head light relay coupler 1 Disconnect 14 Head light relay 1 Disconnect 15 Fuse box 1 16 Battery box 1 17 Turn signal relay coupler 1 Disconnect 18 Turn signal relay...

Page 125: ...GENERAL CHASSIS 4 4 21 Lean angle sensor coupler 1 Disconnect 22 Lean angle sensor 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks ...

Page 126: ...emoving the air filter case Order Job Parts to remove Q ty Remarks 1 Air filter case cover 1 2 Air filter element 1 3 Air filter case 1 4 Crankcase breather hose 1 Disconnect For installation reverse the removal proce dure ...

Page 127: ...t 2 3 Passenger seat bracket 1 4 Passenger seat guide 1 5 Rear fender 1 6 Mudguard front 1 7 Rear turn signal light bracket cover 1 8 Rear turn signal light coupler 2 Disconnect 9 License plate light coupler 1 Disconnect 10 Rear turn signal light 2 11 Rear turn signal light bracket 1 12 Tail brake light assembly 1 13 License plate light assembly 1 14 Mudguard rear 1 15 Reflector bracket 1 For inst...

Page 128: ... Parts to remove Q ty Remarks TIP Place the vehicle on a suitable stand so that the front wheel is elevated 1 Front brake caliper 1 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Front brake disc 1 For installation reverse the removal proce dure ...

Page 129: ...FRONT WHEEL 4 8 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 130: ...wheel hub b Remove the oil seals 1 with a flathead screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire...

Page 131: ... diameter of the wheel bearing outer race and oil seal 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 Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front w...

Page 132: ...tion install a heavier weight 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 station ary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC 1 Install Front brake disc TIP Tighten the brake disc bolts in stages ...

Page 133: ... times and check if the front fork rebounds smoothly TIP Tighten the front wheel axle pinch bolts to specification twice Tighten the inside and out side bolts alternately starting with the inside bolt 6 Install Front brake caliper WARNING EWA3D81008 Make sure the brake hose is routed prop erly Front wheel axle 59 Nm 5 9 m kgf 43 ft lbf Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft lbf Front br...

Page 134: ...Muffler Refer to ENGINE REMOVAL on page 5 1 1 Rear brake caliper 1 2 Rear brake pad 2 3 Brake pad spring 2 4 Drive belt upper guard 1 5 Belt case stay 1 6 Drive belt adjusting locknut 2 Loosen 7 Drive belt adjusting nut 2 Loosen 8 Plate 2 9 Rear wheel axle nut 1 10 Washer 2 11 Rear wheel axle 1 12 Right drive belt puller 1 13 Left drive belt puller 1 14 Collar caliper 1 Black ...

Page 135: ... 4 14 15 Rear brake caliper bracket 1 16 Collar right 1 Black 17 Collar left 1 Silver 18 Rear wheel 1 For installation reverse the removal proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks ...

Page 136: ...rder Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel pulley 1 3 Oil seal 1 4 Circlip 1 5 Rear wheel drive hub 1 6 Circlip 1 7 Bearing 1 8 Collar 1 9 Bearing 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 For installation reverse the removal proce dure ...

Page 137: ...REAR WHEEL 4 16 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Oil seal 1 4 Circlip 1 5 Bearing 1 6 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 138: ...CHECKING THE FRONT WHEEL on page 4 9 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 17 and CHECKING THE WHEELS on page 3 17 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 9 EAS3D81016 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace EAS22110 CHECKING THE REAR WHEEL DRI...

Page 139: ...l lips 2 Install Rear brake disc TIP Apply locking agent LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 3 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 36 4 Install Rear wheel axle Washer Rear wheel axle nut TIP Temporarily tighten the wheel axle nut 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BEL...

Page 140: ...arts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Front brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Front brake pad spring 1 5 Front brake pad support 2 For installation reverse the removal proce dure ...

Page 141: ...cylinder reservoir cap 1 3 Brake master cylinder reservoir diaphragm holder 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Spring 1 7 Front brake light switch connector 2 Disconnect 8 Front brake hose union bolt 1 9 Washer 2 10 Front brake hose 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 13 Front brake light switch 1 For installation reverse the re...

Page 142: ...T BRAKE 4 21 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 143: ... remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Front brake hose union bolt 1 2 Washer 2 3 Front brake hose 1 4 Front brake caliper bracket bolt 2 5 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 144: ...y Remarks 1 Front brake caliper retaining bolt 2 2 Brake pad spring 1 3 Brake pad 2 4 Brake pad support 2 5 Brake caliper bracket 1 6 Brake caliper piston 2 7 Brake caliper piston dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 145: ...SC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right to ensure that the fr...

Page 146: ...ose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw to specification d Install new brake pads and a new brake pad spring 3 Lubricate Front brake caliper retaining bolts ECA14150 Do not allow grease to contact the brake pads Remove any exc...

Page 147: ...als 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA3D81009 Cover the brake caliper pistons with a rag Be careful not to get injured when the piston are expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seals and brake caliper piston seals EAS22390 CHECKING THE ...

Page 148: ...never a brake caliper is disassem bled replace the brake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brake caliper 1 temporarily Washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 35 ECA14170 When in...

Page 149: ...to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 7 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylin der drain the brake fluid from the entire brake system 1 Remove Front brake hose union bolt 1 ...

Page 150: ...within the angle shown in the illustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables and leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Othe...

Page 151: ...em Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 LOWER a ...

Page 152: ...REAR BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure ...

Page 153: ...Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Washer 2 9 Brake switch coupler 1 Disconnect 10 Pedal step assembly right 1 11 Brake switch return spring 1 12 Brake switch 1 13 Rear brake master cylinder 1 14 Plastic clamp 4 15 Rear brake hose bracket 1 16 Rear brake hose 1 For in...

Page 154: ...sassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 155: ...move Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper retaining bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure ...

Page 156: ...embling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 157: ...ck Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 24 TIP Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace R...

Page 158: ... 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Washers 2 Rear brake hose 3 TIP Put the end of the brake hose into a container and pump out the b...

Page 159: ...rake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install...

Page 160: ... lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 7 Check Brake pedal operat...

Page 161: ... 3 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 35 ECA3D81005 When installing the brake hose onto the brake master cylinder make sure the brake pipe a touches the projection b on the brake caliper bracket as shown 2 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use o...

Page 162: ...EM on page 3 15 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 6 Adjust Brake pedal adjusting bolt position Refer to ADJUSTING THE REAR DISC BRAKE on p...

Page 163: ...eft 1 2 Plastic clamp 4 3 Right handlebar switch 1 4 Throttle cable 2 Disconnect 5 Grip end 2 6 Throttle grip 1 7 Clutch switch coupler 1 Disconnect 8 Left handlebar switch 1 9 Handlebar grip 1 10 Clutch cable 1 Disconnect 11 Clutch lever 1 12 Clutch lever holder 1 13 Clutch switch 1 14 Upper handlebar holder 2 15 Handlebar 1 16 Lower handlebar holder 2 For installation reverse the removal proce d...

Page 164: ...pport the vehicle so that there is no danger of it falling over 2 Install Handlebar 1 Upper handlebar holders 2 ECA3D81006 First tighten the bolts on the front side of the upper 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 end of the upper handlebar holder with ...

Page 165: ...Throttle cable decelerator cable 1 to the right handlebar switch 2 TIP Rotate the right handlebar switch and screw it onto the end of the throttle cable 7 Install Right handlebar switch 1 TIP Align the projection a on the right handlebar switch with the hole b in the handlebar 8 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Refer to INSTALLING THE FRONT BRAKE MASTER CY...

Page 166: ...HANDLEBAR 4 45 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 28 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in ...

Page 167: ...FRONT WHEEL on page 4 7 Rear handlebar holder Refer to HANDLEBAR on page 4 42 1 Brake hose guide 1 2 Brake hose guide bracket 1 3 Front fender 1 4 Main switch coupler 2 Disconnect 5 Upper bracket pinch bolt 2 Loosen 6 Cap bolt 1 Loosen 7 Steering stem nut 1 8 Upper bracket 1 9 Main switch cover 1 10 Main switch cover holder 1 11 Upper front fork cover 1 12 Upper front fork cover spacer 1 13 Cable ...

Page 168: ...ORK 4 47 15 Lower bracket pinch bolt 2 Loosen 16 Lower front fork cover 1 17 Front fork leg 1 For installation reverse the removal proce dure Removing the front fork legs Order Job Parts to remove Q ty Remarks ...

Page 169: ...nt fork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Inner tube 1 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Oil flow stopper 1 17 Outer tube 1 For assembly reverse the disassembly pro cedure ...

Page 170: ...hile drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer TIP While holding the damper rod with the damper rod holder 2 and T handle 3 loosen the damper rod bolt 4 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft j...

Page 171: ...allow any foreign material to enter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Ou...

Page 172: ...umbered side of the oil seal faces up TIP Before installing the oil seal lubricate its lips with lithium soap based 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 to protect the oil seal during installation 8 Install Oil seal clip 1 Damper rod bolt 30 Nm 3 0 m kgf 22 ft lbf LOCTITE Damper rod ...

Page 173: ...ng Spring seat Spacer Cap bolt along with the O ring TIP Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt Tighten the cap bolt specified torque when installing the front fork with upper bracket EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Lower front fork cover 1 Front fork leg 2 Upp...

Page 174: ...and groove b in the upper front fork cover 2 with the lower front fork cover bolts 3 6 Tighten Steering stem nut Cap bolt Upper bracket pinch bolt WARNING EWA13680 Make sure the brake hose is routed prop erly Lower bracket pinch bolt 45 Nm 4 5 m kgf 32 ft lbf Lower front fork cover bolt 18 Nm 1 8 m kgf 13 ft lbf Steering stem nut 110 Nm 11 m kgf 80 ft lbf Cap bolt 23 Nm 2 3 m kgf 17 ft lbf Upper b...

Page 175: ...Air temperature sensor coupler 1 Disconnect 3 Front turn signal light bracket 1 4 Air temperature sensor 1 5 Front brake hose holder 1 6 Front brake hose joint 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Upper bearing cover 1 13 Upper bearing inner race 1 14 Upper bearing 1 15 Washer 1 16 Lower bearing 1 17 Dust seal 1 18 Lower bearing inner rac...

Page 176: ...STEERING HEAD 4 55 19 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 177: ...gs Bearing races a Remove the bearing races from the steer ing head pipe with a long rod 1 and ham mer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing races ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whenever the ...

Page 178: ...ont brake hose joint 1 Front brake hose holder 2 TIP Make sure that the projection a on the lower bracket contacts the side b of the front brake hose joint 1 Align the projection c on the front brake hose holder with the hole d in the lower bracket 4 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 46 Recommended lubricant Lithium soap based grease ...

Page 179: ...page 5 1 Rear wheel Refer to REAR WHEEL on page 4 13 1 Connecting arm nut Washer Bolt 2 2 2 2 Connecting arm 2 3 Rear shock absorber assembly lower nut Washer Bolt Collar 1 1 1 1 4 Rear shock absorber assembly upper nut Bolt 1 1 5 Rear shock absorber assembly 1 6 Relay arm nut Bolt Spacer Collar Washer 1 1 1 1 1 7 Relay arm 1 8 Spacer 1 9 Oil seal 2 10 Bearing 2 11 Bearing 1 12 Bearing 1 For insta...

Page 180: ...s posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 15 20 mm 0 60 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support th...

Page 181: ...ting Replace 3 Check Spacers Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Spacers Bearings 2 Install Bearings 1 2 and 3 to the relay arm Oil seals 4 to the relay arm EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacer 2 Tighten Relay arm nut 3 Install Rear shock absorber assembly Rear shock absorber assembly upper bolt Rear shock absorber assembly lowe...

Page 182: ... nut 5 Install Connecting arms Connecting arms bolts TIP When installing the connecting arms lift up the swingarm 6 Tighten Connecting arm nuts Rear shock absorber assembly upper nut 48 Nm 4 8 m kgf 35 ft lbf Rear shock absorber assembly lower nut 48 Nm 4 8 m kgf 35 ft lbf Connecting arm nut 59 Nm 5 9 m kgf 43 ft lbf ...

Page 183: ...arms Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 58 Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Drive belt lower guard 1 2 Right side cover lower 1 3 Pivot shaft nut cover 1 4 Pivot shaft nut 1 5 Pivot shaft 1 6 Swingarm 1 7 Spacer 1 8 Bearing 2 9 Dust cover 2 10 Washer 2 11 Spacer 1 12 Bearing 2 13 Brake hose holder 1 For installation reverse the removal proce dure ...

Page 184: ...wingarm end free play radial is out of specification check the spacers bear ings washers and dust covers f Check the swingarm circumference move ment by moving the swingarm up or down If the swingarm circumference movement is not smooth or if it is stuck check the spac ers bearings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot sha...

Page 185: ...rs Dust covers Pivot shaft 2 Install Bearings 1 3 Install Pivot shaft nut 4 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 19 Recommended lubricant Lithium soap based grease 2 Swingarm A Left side B Right side Installed depth a 0 1 0 mm 0 0 04 in Pivot shaft nut 85 Nm 8 5 m kgf 61 ft lbf ...

Page 186: ...arm Refer to SWINGARM on page 4 62 Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 58 1 Air duct 1 2 Drive pulley cover 1 3 Drive belt 1 4 Drive pulley nut 1 5 Washer 1 6 Drive pulley 1 7 Speed sensor 1 8 Speed sensor coupler 1 Disconnect 9 Speed sensor bracket 1 10 Lead bracket 1 For installation reverse the removal proce dure ...

Page 187: ...t ECA14690 To protect the drive belt from damage handle it with care The drive belt can not be bent smaller than 125 mm 4 92 in a The removed drive belt can not be twisted inside out 3 Check Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pulleys as a set EAS23540 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1 Install Drive belt ECA14710 Align the mark of the drive belt with the...

Page 188: ...BELT DRIVE 4 67 When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 19 a ...

Page 189: ...NDER HEADS 5 22 MEASURING THE COMPRESSION PRESSURE 5 23 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES AND VALVE GUIDES 5 26 CHECKING THE VALVE SEATS 5 28 CHECKING THE VALVE SPRINGS 5 30 INSTALLING THE VALVES 5 30 CYLINDERS AND PISTONS 5 33 REMOVING THE PISTONS 5 34 CHECKING THE CYLINDERS AND PISTONS 5 34 CHECKING THE PISTON RINGS 5 35 CHECKING THE PISTON PINS 5 36 INST...

Page 190: ...OTOR 5 59 CRANKCASE 5 60 DISASSEMBLING THE CRANKCASE 5 63 CHECKING THE CRANKCASE 5 63 CHECKING THE BEARINGS AND OIL SEAL 5 63 CHECKING THE OIL DELIVERY PIPES 5 63 CHECKING THE TIMING CHAINS 5 63 CHECKING THE OIL PUMP DRIVEN SPROCKET 5 63 INSTALLING THE BEARING RETAINERS 5 63 ASSEMBLING THE CRANKCASE 5 64 OIL PUMP 5 66 CHECKING THE OIL PUMP 5 67 CHECKING THE RELIEF VALVE 5 67 CHECKING THE OIL STRAI...

Page 191: ...INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 78 ...

Page 192: ... to REAR BRAKE on page 4 31 1 O2 sensor coupler 1 Disconnect 2 Muffler 1 3 Clamp 1 4 Gasket 1 5 Exhaust pipe stay 1 6 Exhaust pipe 1 7 Silencer plate 1 8 Gasket 2 9 Clamp 7 10 Exhaust pipe protector 1 1 11 Exhaust pipe protector 3 1 12 Exhaust pipe protector 2 1 13 Exhaust pipe protector 4 1 14 Grommet 2 15 O2 sensor 1 16 Muffler bracket 1 ...

Page 193: ...ENGINE REMOVAL 5 2 For installation reverse the removal proce dure Removing the muffler and exhaust pipe Order Job Parts to remove Q ty Remarks ...

Page 194: ...ver clamp screws always replace them with new ones if they are loosened 2 Install Gasket 1 to muffler TIP Install the gasket with the chamfer a located on an inner rim of the gasket and the chamfer b located on an outer rim of the gasket as shown Exhaust pipe cover clamp screw 5 Nm 0 5 m kgf 3 6 ft lbf Installed depth of gasket c 3 5 mm 0 14 in New New ...

Page 195: ... Disconnect 2 Sidestand 1 3 Shift arm 1 4 Shift rod 1 5 Left footrest assembly 1 6 Front cylinder upper plastic cover 1 7 Front cylinder lower plastic cover 1 8 Collar 4 9 Grommet 4 10 Rear cylinder left plastic cover 1 11 Rear cylinder right plastic cover 1 12 Rear cylinder left plastic cover bracket 1 13 Rear cylinder right plastic cover bracket 1 14 Grommet 6 15 Ground lead 1 Disconnect 16 Neut...

Page 196: ...ENGINE REMOVAL 5 5 19 Dowel pin 2 For installation reverse the removal proce dure Removing the sidestand and drive pulley housing Order Job Parts to remove Q ty Remarks ...

Page 197: ...LLING THE SHIFT ARM 1 Install Shift arm 1 TIP Align the I mark a in the shift shaft with the punch mark b in the shift arm 2 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 22 Front cylinder lower plastic cover bolt 20 Nm 2 0 m kgf 14 ft lbf Front cylinder upper plastic cover screw 5 Nm 0 5 m kgf 3 6 ft lbf Rear cylinder left plastic cover bracket bolt 20 Nm 2 0 m kgf 14 ft lb...

Page 198: ...r motor lead Refer to ELECTRIC STARTER on page 5 56 Rear brake hose Refer to REAR BRAKE on page 4 31 1 Oil level switch coupler 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankcase breather hose 1 4 Rectifier regulator coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Neutral switch connector 1 Disconnect 7 Horn connector 2 Disconnect 8 Horn 1 9 Engine temperature sensor c...

Page 199: ... bolt rear side 2 6 Down tube 1 7 Engine mounting nut rear upper side 1 8 Engine mounting bolt rear upper side 1 9 Engine mounting nut rear lower side 1 10 Engine mounting bolt rear lower side 1 11 Engine bracket bolt rear upper side 2 12 Engine bracket rear upper side 1 13 Engine bracket bolt rear lower side 2 14 Engine bracket rear lower side 1 15 Engine mounting nut front upper side 1 16 Engine...

Page 200: ...ENGINE REMOVAL 5 9 For installation reverse the removal proce dure Removing the down tube and engine Order Job Parts to remove Q ty Remarks ...

Page 201: ...E to the threads of the engine bracket bolts front upper side engine bracket bolts rear lower side engine bracket bolts rear upper side down tube bolts front side and down tube bolts rear side Do not tighten the bolts and nuts 2 Tighten Engine bracket bolts front upper side 3 Engine bracket bolts rear lower side 7 Engine bracket bolts rear upper side 9 Down tube bolts front side 15 Down tube bolts...

Page 202: ...g nut front upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting nut rear lower side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting nut rear upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting nut front lower side 88 Nm 8 8 m kgf 64 ft lbf ...

Page 203: ...Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 1 Tappet cover 4 2 O ring 4 3 Front cylinder side cover 1 4 Front cylinder side cover gasket 1 5 Rear cylinder side cover 1 6 Rear cylinder side cover gasket 1 For installation reverse the removal proce dure ...

Page 204: ...ting screw 8 4 Timing chain tensioner 2 5 Timing chain tensioner gasket 2 6 Camshaft bolt 2 7 Camshaft sprocket 2 8 Camshaft retainer 2 9 Front cylinder camshaft 1 10 Rear cylinder camshaft 1 11 Intake rocker arm shaft 2 12 Intake rocker arm 2 13 Exhaust rocker arm shaft 2 14 Exhaust rocker arm 2 For installation reverse the removal proce dure ...

Page 205: ...et with the arrow mark d on the front cylinder head 2 Remove Front cylinder timing chain tensioner 1 TIP Never remove a timing chain tensioner when the engine is mounted 3 Remove Front cylinder camshaft sprocket TIP While holding the camshaft sprocket with the rotor holding tool 1 loosen the camshaft sprocket bolt 2 To prevent the timing chain from falling into the crankcase fasten it with a wire ...

Page 206: ...arrow mark d on the rear cylinder head 7 Remove Rear cylinder timing chain tensioner Rear cylinder camshaft sprocket Camshaft retainer Rear cylinder camshaft Intake rocker arm shaft Exhaust rocker arm shaft Intake rocker arm Exhaust rocker arm TIP Never remove a timing chain tensioner when the engine is mounted Remove the parts using the same procedure as for the front cylinder camshaft and rocket...

Page 207: ...lue discoloration excessive wear pitting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace Camshaft lobe dimensions Intake A 42 470 42 570 mm 1 6720 1 6760 in Limit 42 370 mm 1 6681 in Intake B 37 041 37 141 mm 1 4583 1 4622 in Limit 36 941 mm 1 4544 in Exha...

Page 208: ...Timing chain tensioner gasket 5 Timing chain tensioner rod 6 Damage wear Replace the defective part s EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts 1 Lubricate Rocker arm shafts 2 Install Rocker arms Rocker arm shafts 3 Lubricate Camshaft 4 Install Camshaft 1 Camshaft retainer 2 TIP The front cylinder camshaft is identifie...

Page 209: ...der head When installing the front cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side d Remove the wire from the timing chain 6 Tighten Front cylinder camshaft sprocket bolt 1 TIP While holding the camshaft sprocket with the rotor holding tool 2 tighten the camshaft sprocket bolt 7 Install Front cylinder timing chain tensioner gas ket 1 Front cylin...

Page 210: ... not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing TIP To position the rear cylinder piston at TDC on the compression stroke align the I mark c on the camshaft sprocket with the arrow mark d on the rear cylinder head When installing the rear cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the intake side d Remove the...

Page 211: ...fication Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 5 EAS5S71009 INSTALLING THE CYLINDER HEAD COV ERS 1 Install Rear cylinder side cover Tappet covers 2 Install Front cylinder side cover Tappet covers Rear cylinder timing chain ten sioner bolt 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt 24 Nm 2 4 m kgf 17 ft lbf New Rear cylinder side cover bolt 10 Nm 1 0 m kgf 7 2 ft l...

Page 212: ...perature sensor 1 3 Cylinder head nut 8 4 Cylinder head bolt 4 5 Front cylinder head 1 6 Rear cylinder head 1 7 Dowel pin 4 8 Cylinder head gasket 2 9 Timing chain guide exhaust side 1 10 Timing chain guide intake side 1 11 Rear exhaust pipe joint cover 1 12 Rear exhaust pipe joint 1 13 Gasket 1 For installation reverse the removal proce dure ...

Page 213: ...mag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder heads Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place 400 600 grit wet sandpaper on a surface p...

Page 214: ...l minutes and then turn it off 3 Remove Rear cylinder right plastic cover Refer to ENGINE REMOVAL on page 5 1 4 Disconnect Spark plug caps 5 Remove Spark plug ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 6 Install Compression gauge 1 Extension 2 TIP Use extension 90890 04136 for...

Page 215: ...ression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table 8 Install Spark plug 9 Connect Spark plug caps 10 Install Rear cylinder right plastic cover Refer to ENGINE REMOVAL on page 5 1 Standard compression pres sure at sea level 1400 kPa 400 r min 14 0 kgf cm2 400 r min 199 1 psi 400 r min Minimum m...

Page 216: ...o remove Q ty Remarks The following procedure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 21 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure ...

Page 217: ...e cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The fo...

Page 218: ... and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 00...

Page 219: ...ng procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylin der head Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04...

Page 220: ...ing compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands...

Page 221: ...ecification Replace the valve spring EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone Free length intake 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Free length exhaust 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Installed compression spring force intake 171 197 N 17 44 20 09 kgf 38 45 44 30 lbf Installed c...

Page 222: ...lled in its origi nal place Install the valve springs with the larger pitch a facing up 5 Install Valve cotters TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil New a Larger pitch b Smaller pitch Valve spring compressor 90890 ...

Page 223: ...ALVES AND VALVE SPRINGS 5 32 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA13800 Hitting the valve tip with excessive force could damage the valve ...

Page 224: ...rts to remove Q ty Remarks Cylinder heads Refer to CYLINDER HEADS on page 5 21 1 Front cylinder 1 2 Rear cylinder 1 3 Front cylinder gasket 1 4 Rear cylinder gasket 1 5 Dowel pin 4 6 Circlip 4 7 Piston pin 2 8 Piston 2 9 Top ring 2 10 2nd ring 2 11 Oil ring 2 For installation reverse the removal proce dure ...

Page 225: ...with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons 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 with the cyl...

Page 226: ...ng side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder a 10 0 mm 0 39 in b 85 6 mm 3 37 in A Intake side B Exhaust side Piston Diameter D 84 955 84 970 mm 3 3447 3 3453 in b 8 mm 0 31 in from the bottom...

Page 227: ...asure Piston pin bore diameter b Out of specification Replace the pis ton 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 10 mm 0 39 in Piston ring Top ring End gap installed 0 15 0 30 mm 0 0059 0 0118 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315 in Oil ring End gap ins...

Page 228: ...iston faces towards the front side of the cylinder Before installing the circlips cover the crank case opening with a clean rag to prevent the clips from falling into the crankcase Install the circlips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Lubricate Piston Piston rings Cylinder with the recommended lubrican...

Page 229: ...S AND PISTONS 5 38 6 Install Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide through the timing chain cavity ...

Page 230: ...over Refer to BELT DRIVE on page 4 65 Speed sensor Refer to BELT DRIVE on page 4 65 Crankshaft position sensor coupler Refer to ENGINE REMOVAL on page 5 1 Rectifier regulator coupler Refer to ENGINE REMOVAL on page 5 1 Engine oil Drain 1 Damper cover 1 2 Generator cover damper 1 3 Crankshaft end accessing screw 1 4 Timing mark accessing screw 1 5 Oil level gauge 1 6 Generator cover 1 7 Generator c...

Page 231: ...GENERATOR AND STARTER CLUTCH 5 40 For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks ...

Page 232: ... Parts to remove Q ty Remarks 1 Generator rotor 1 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Starter clutch idle gear 2 shaft 1 6 Starter clutch idle gear 2 1 7 Starter clutch idle gear 1 shaft 1 8 Starter clutch idle gear 1 1 For installation reverse the removal proce dure ...

Page 233: ...f the starter clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gears Starter clu...

Page 234: ...S24500 INSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 TIP W...

Page 235: ...CLUTCH 5 44 EAS5S71011 INSTALLING THE GENERATOR COVER 1 Install TIP Temporally tighten a and b and then tighten the generator cover bolts in the order shown in the illustration Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 236: ... assembly Refer to REAR BRAKE on page 4 31 Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 Down tube Refer to ENGINE REMOVAL on page 5 1 Clutch cable Refer to ENGINE REMOVAL on page 5 1 Engine oil Drain 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Primary drive gear plastic cover 1 1 5 Primary drive gear plastic cover 2 1 6 Primary drive gear cover 1 7 Protector cover 1 8 Air filter case br...

Page 237: ... Primary drive gear nut 1 13 Lock washer 1 14 Spacer 1 15 Primary drive gear 1 16 Woodruff key 1 For installation reverse the removal proce dure Removing the primary drive gear Order Job Parts to remove Q ty Remarks ...

Page 238: ...ving the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 6 Oil seal retainer 1 7 Oil seal 1 For installation reverse the removal proce dure ...

Page 239: ...1 6 Bearing 1 7 Friction plate 1 2 Inside diameter 124 mm 4 88 in 8 Clutch plate 8 9 Friction plate 2 7 Inside diameter 124 mm 4 88 in 10 Clutch boss nut 1 11 Conical spring washer 1 12 Clutch boss 1 13 Thrust washer 1 1 14 Clutch housing 1 15 Bearing 1 16 Collar 1 17 Oil pump drive chain 1 18 Oil pump drive sprocket 1 19 Thrust washer 2 1 For installation reverse the removal proce dure ...

Page 240: ...ot allow the sheave holder to touch the projection on the generator rotor EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set TIP Measure each friction plate at four places Universal clu...

Page 241: ...2 Check Clutch spring plate seat Damage Replace EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing TIP Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines D...

Page 242: ...eck Pull rod bearing Damage wear Replace EAS5S71001 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN 1 Check Oil pump drive sprocket Cracks damage wear Replace the oil pump drive chain and oil pump drive and driven sprockets as a set 2 Check Oil pump drive chain Damage stiffness Replace the oil pump drive chain and oil pump drive and driven sprockets as a set EAS25230 INSTALLING THE P...

Page 243: ... drive gear teeth mesh correctly After installing the clutch housing make sure that the primary drive gear 2 and clutch housing primary driven gear 3 are aligned as shown in the illustration 3 Install Clutch boss 1 Washer Conical spring washer 2 Clutch boss nut 3 TIP Lubricate the clutch boss nut threads and conical spring washer mating surfaces with engine oil Install the conical spring washer wi...

Page 244: ...s and in a crisscross pattern 7 Install Primary drive gear cover TIP Temporally tighten a and b and then tighten the primary drive gear cover bolts in the order shown in the illustration 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP Make sure that the mark a on the pull lever is facing forward When installing the pull lever push it and check that its punch mark b aligns with the ma...

Page 245: ...Refer to BELT DRIVE on page 4 65 Shift arm Refer to ENGINE REMOVAL on page 5 1 Primary drive gear cover Refer to CLUTCH on page 5 45 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 Shift shaft spring 1 7 Shift shaft spring stopper 1 8 Oil seal 1 9 Bearing 1 For installation reverse the removal proce dure ...

Page 246: ...ns roughly Replace the stop per lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 TIP Lubricate the oil seal lips with lithium soap based grease Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum segment assembly Hook the end of the shift shaft spring onto the sh...

Page 247: ...IC STARTER 5 56 EAS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 248: ...otor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Armature assembly 1 4 Starter motor yoke 1 5 Gasket 2 6 Starter motor rear cover 1 7 Brush set assembly 1 8 O ring 1 For assembly reverse the disassembly pro cedure ...

Page 249: ...e starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor 4 Measure Brush length a Out of specification Replace the brush set assembly 5 Measure Brush spring force Out of specification Replace the brush set assembly Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Model 88 Multimet...

Page 250: ...wear Replace the starter motor EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Brush set assembly 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers ...

Page 251: ... page 5 33 Clutch Refer to CLUTCH on page 5 45 Primary drive gear Refer to CLUTCH on page 5 45 Shift shaft Refer to SHIFT SHAFT on page 5 54 1 Oil level switch 1 2 Engine oil drain bolt 1 3 Neutral switch 1 4 Timing chain guide 2 5 Timing chain 2 6 Spacer 1 7 Oil filter cartridge 1 8 Oil delivery pipe 1 1 9 Oil delivery pipe 2 1 10 Oil pump driven sprocket 1 For installation reverse the removal pr...

Page 252: ...ove Q ty Remarks 1 Oil baffle plate 1 1 2 Left crankcase 1 3 Dowel pin 2 4 Joint pipe 1 5 O ring 2 6 Oil baffle plate 2 1 7 Gasket 1 8 Right crankcase 1 9 Stud bolt 6 l 239 mm 9 41 in 10 Stud bolt 2 l 210 mm 8 27 in For installation reverse the removal proce dure ...

Page 253: ...arts to remove Q ty Remarks Oil pump assembly Refer to OIL PUMP on page 5 66 Crankshaft Refer to CRANKSHAFT on page 5 69 Transmission Refer to TRANSMISSION on page 5 74 1 Bearing retainer 2 2 Oil seal 1 3 Bearing 5 For installation reverse the removal proce dure ...

Page 254: ...d air EAS3D81029 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace Oil seals Damage wear Replace EAS5S71002 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes and joint pipe 1 Check Oil delivery pipe Joint pipe Damage Replace Obstruction Wash and blow ...

Page 255: ...case bolts M6 Oil baffle plate 1 bolts TIP Apply locking agent LOCTITE to the threads of the right crankcase bolts and oil baffle plate 1 bolts Tighten the crankcase bolts in the proper tightening sequence as shown in the illustra tion M10 110 mm bolts M6 120 mm bolts a Oil baffle plate 1 bolts b M6 80 mm bolts Bearing retainer bolt 12 Nm 1 2 m kgf 8 7 ft lbf LOCTITE Yamaha bond No 1215 90890 8550...

Page 256: ...CRANKCASE 5 65 5 Apply Engine oil onto the crankshaft pin bearings and oil delivery holes 6 Check Crankshaft and transmission operation Rough movement Repair ...

Page 257: ...Crankcase Refer to CRANKCASE on page 5 60 1 Relief valve assembly 1 2 Oil pump assembly 1 3 Dowel pin 2 4 Oil pump housing 1 5 Dowel pin 2 6 Impeller shaft 1 7 Pin 1 8 Oil pump inner rotor 1 9 Oil pump outer rotor 1 10 Oil pump housing cover 1 11 Bearing 1 For installation reverse the removal proce dure ...

Page 258: ...gh movement Repeat steps 1 and 2 or replace the oil pump assembly EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage wear Replace the relief valve assembly Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump hous ing clearance 0 09 0 19 mm 0 0035 0 0075 in Limit 0 26 mm 0 0...

Page 259: ...p housing 4 TIP When installing the inner rotor align the pin in the impeller shaft with the grooves a in the inner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 67 EAS5S71004 INSTALLING THE OIL PUMP ASSEMBLY 1 Install Oil pump assembly ECA5S71002 After tightening the bolts make sure the oil pump assembly turns smoothly Recommended lubricant Engine oil Oil pump housing ...

Page 260: ...nkshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 60 1 Crankshaft 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bearing 2 For installation reverse the removal proce dure ...

Page 261: ...cedure applies to all of the connecting rods ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their orig inal positions a Clean the big end bearings crankshaft pin and the inside of the connecting rod halves b Install the big end upper bearing i...

Page 262: ...ING RODS on page 5 70 g Measure the compressed Plastigauge width e on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 4 Select Big end bearings P1 P2 TIP The numbers a on the connecting rods are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crankshaft illustration Fo...

Page 263: ...t pin Big end bearings Connecting rod inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pin TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection c on each con necting ...

Page 264: ...5S71003 When a bolt is tightened more than the specified angle do not loosen and then retighten it Replace the bolt with a new one and per form the procedure again ECA5S71003 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEM BLY 1 Install Crankshaft assembly ECA5S71004 To avoid scratchi...

Page 265: ...Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 60 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift drum assembly 1 4 Shift fork 1 2 5 Shift fork 2 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure ...

Page 266: ...1 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed lock washer retainer 1 5 4th pinion gear 1 6 Collar 1 7 Toothed washer 1 8 Circlip 1 9 3rd pinion gear 1 10 Circlip 1 11 Toothed washer 1 12 5th pinion gear 1 13 Collar 1 14 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure ...

Page 267: ...t wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Toothed washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Circlip 1 13 Toothed washer 1 14 2nd wheel gear 1 15 Collar 1 16 Drive axle 1 For assembly reverse the disassembly pro cedure ...

Page 268: ...gh movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum assembly Shift drum bearing 2 Damage pitting Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a cente...

Page 269: ...nds a rest on the sides of a spline b with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer in the groove a in the drive axle align the projec tion b on the retainer with an axle spline c and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks d...

Page 270: ...heck Transmission Rough movement Repair TIP Apply molybdenum disulfide grease to each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely ...

Page 271: ...EL PUMP 6 4 THROTTLE BODIES 6 6 CHECKING THE INJECTORS 6 9 INSTALLING THE INJECTORS 6 9 CHECKING THE INJECTOR PRESSURE 6 9 CHECKING THE THROTTLE BODIES 6 10 CHECKING AND CLEANING THE THROTTLE BODIES 6 10 CHECKING THE INTAKE MANIFOLD JOINTS 6 11 CHECKING THE FUEL PRESSURE 6 11 ADJUSTING THE THROTTLE POSITION SENSOR 6 11 INSTALLING THE INTAKE MANIFOLD ASSEMBLY 6 12 ...

Page 272: ...e 4 1 1 Fuel tank bracket bolt 2 2 Meter coupler 1 1 Disconnect 3 Meter coupler 2 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel sender coupler 1 Disconnect 6 Fuel hose 1 Disconnect 7 Fuel return hose 1 Disconnect 8 Fuel tank drain hose 1 9 Meter cover 1 10 Meter stay 1 11 Meter assembly 1 12 Fuel tank 1 13 Fuel tank bracket 1 14 Damper 1 15 Fuel pump 1 16 Fuel pump gasket 1 17 Fuel sender 1...

Page 273: ...FUEL TANK 6 2 18 Fuel sender gasket 1 For installation reverse the removal proce dure Removing the fuel tank Order Job Parts to remove Q ty Remarks ...

Page 274: ... to remove Q ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Fuel tank drain hose Refer to FUEL TANK on page 6 1 1 Fuel tank breather hose 1 2 Rollover valve 1 For installation reverse the removal proce dure ...

Page 275: ...emove Fuel pump ECA5S71005 Do not drop the fuel pump or give it a strong shock EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace the fuel pump assembly EAS5S71041 CHECKING THE ROLLOVER VALVE 1 Check Rollover valve 1 Damage faulty Replace TIP Check that air flows smoothly only in the direction of the arrow shown in the illustra tion The rollover val...

Page 276: ...nnector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 ...

Page 277: ...HASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 1 Throttle position sensor coupler 1 Disconnect 2 Intake air pressure sensor hose 1 Disconnect 3 Throttle cable 2 Disconnect 4 ISC idle speed control unit coupler 1 Disconnect 5 Throttle body 1 ECA5S71007 The throttle body should not disassem bled 6 Gasket 1 7 Throttle position sensor 1 For installation reverse the removal proce dure ...

Page 278: ...Refer to FUEL TANK on page 6 1 Throttle body Refer to THROTTLE BODIES on page 6 6 1 Fuel hose 1 2 Clutch cable holder 2 1 3 Fuel injector coupler 2 Disconnect 4 Intake manifold joint clamp screw 2 Loosen 5 Rear cylinder intake manifold joint 1 6 Intake manifold assembly 1 7 Front cylinder intake manifold joint 1 For installation reverse the removal proce dure ...

Page 279: ...ob Parts to remove Q ty Remarks 1 Fuel return hose 1 2 Pressure regulator 1 3 O ring 1 4 Fuel delivery pipe 2 1 5 Fuel delivery hose 1 6 Fuel delivery pipe 1 1 7 Injector 2 8 O ring 2 9 Gasket 2 10 Intake manifold 1 For assembly reverse the disassembly pro cedure ...

Page 280: ... the specified torque 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 7 27 EAS5S71042 INSTALLING THE INJECTORS 1 Install the injectors to the fuel delivery pipes 2 Install a seal onto the end of each injector 3 Install the injector assemblies to the throttle bodies 4 Check the injector pressure after the injec tors are installed to the throttle bodies Refer to CHE...

Page 281: ...e While cleaning avoid injuring your fin gers working around the throttle valve Do not remove the bolts unspecified in the instructions cause of malfunction Do not open the throttle valves quickly Do not subject the throttle bodies to excessive force Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor clean ing solution Do not apply cleaning solvent directly to ...

Page 282: ...e f Measure the fuel pressure Faulty Replace the fuel pump and pres sure regulator EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR TIP Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE POSITION SENSOR on page 7 104 2 Adjust Throttle position sensor angle a Connect the throttle position s...

Page 283: ...stall the front cylinder intake manifold joint with its projection a facing up as shown in the illustration b Install the rear cylinder intake manifold joint 2 to the intake manifold assembly TIP Make sure that the projection b on the rear cylinder intake manifold joint contacts the pro jection c on the intake manifold assembly c Install the intake manifold assembly TIP Lubricate the rear cylinder...

Page 284: ...THROTTLE BODIES 6 13 ...

Page 285: ... 7 21 TROUBLESHOOTING 7 23 FUEL INJECTION SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 ECU SELF DIAGNOSTIC FUNCTION 7 29 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 7 30 TROUBLE SHOOTING CHART 7 31 DIAGNOSTIC MODE 7 32 TROUBLESHOOTING DETAILS 7 33 FUEL PUMP SYSTEM 7 69 CIRCUIT DIAGRAM 7 69 TROUBLESHOOTING 7 71 IMMOBILIZER SYSTEM 7 73 CIRCUIT DIAGRAM 7 73 GENERAL INFORMATION 7 75 PART REPLAC...

Page 286: ...EAN ANGLE SENSOR 7 99 CHECKING THE STARTER MOTOR OPERATION 7 100 CHECKING THE STATOR COIL 7 100 CHECKING THE RECTIFIER REGULATOR 7 101 CHECKING THE HORN 7 101 CHECKING THE OIL LEVEL SWITCH 7 101 CHECKING THE FUEL SENDER 7 102 CHECKING THE FUEL LEVEL WARNING LIGHT 7 102 CHECKING THE OIL LEVEL WARNING LIGHT 7 103 CHECKING THE SPEED SENSOR 7 103 CHECKING THE ENGINE TEMPERATURE SENSOR 7 103 CHECKING T...

Page 287: ......

Page 288: ...IGNITION SYSTEM 7 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 289: ...y unit 13 Neutral switch 14 Sidestand switch 16 ECU engine control unit 17 Rear cylinder ignition coil 18 Spark plug 19 Front cylinder ignition coil 24 Crankshaft position sensor 29 Lean angle sensor 57 Right handlebar switch 59 Engine stop switch 69 Ignition fuse ...

Page 290: ... flow to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch is closed The transmission is in neutral the neutral switch is closed and the sidestand is do...

Page 291: ...GNITION SYSTEM 7 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 Relay unit diode 11 Neutral switch ...

Page 292: ...TERY on page 7 92 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Regap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 7 98 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7 98 Replace the spark plug cap s 6 ...

Page 293: ...KING THE SWITCHES on page 7 87 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE DIODES on page 7 97 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 99 Replace the lean angle sensor 14 Check the entire ignition s...

Page 294: ...ELECTRIC STARTING SYSTEM 7 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 295: ...se 5 Battery 6 Starter motor 7 Starter relay 10 Relay unit 11 Starting circuit cut off relay 13 Neutral switch 14 Sidestand switch 49 Left handlebar switch 50 Clutch switch 57 Right handlebar switch 59 Engine stop switch 60 Start switch 69 Ignition fuse ...

Page 296: ...osed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions ...

Page 297: ...IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Starter relay 12 Start switch 13 Starter motor ...

Page 298: ...eplace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 7 100 The starter motor is OK Perform the electric starting system troubleshoot ing starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 58 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE...

Page 299: ...KING THE SWITCHES on page 7 87 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the right handlebar switch 14 Check the entire starting system s...

Page 300: ...CHARGING SYSTEM 7 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 301: ...CHARGING SYSTEM 7 14 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Battery ...

Page 302: ...ND CHARGING THE BATTERY on page 7 92 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 100 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 101 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to C...

Page 303: ...CHARGING SYSTEM 7 16 ...

Page 304: ...LIGHTING SYSTEM 7 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 305: ...tion meter 38 Meter light 39 High beam indicator light 43 Accessory light OPTION 44 Headlight relay 45 Auxiliary light 46 Headlight 49 Left handlebar switch 53 Pass switch 54 Dimmer switch 66 License plate light 67 Tail brake light 69 Ignition fuse 70 Parking lighting fuse 71 Signaling system fuse 72 Headlight fuse ...

Page 306: ...0 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight signaling system ignition and taillight Refer to CHECKING THE FUSES on page 7 91 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 92 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the main switch ...

Page 307: ...LIGHTING SYSTEM 7 20 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 7 17 Properly connect or repair the lighting system s wiring Replace the ECU or meter assembly ...

Page 308: ...SIGNALING SYSTEM 7 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 309: ...uel level warning light 40 Turn signal indicator light 42 Fuel sender 47 Horn 48 Turn signal relay 49 Left handlebar switch 51 Turn signal switch 52 Horn switch 55 Front right turn signal light 56 Front left turn signal light 57 Right handlebar switch 58 Front brake light switch 64 Rear right turn signal light 65 Rear left turn signal light 67 Tail brake light 68 Rear brake light switch 70 Parking...

Page 310: ...use s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 92 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the main switch immobilizer unit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signal ing system s wiring Check th...

Page 311: ... front brake light switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the rear brake light switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the turn ...

Page 312: ...onnect or repair the signal ing system s wiring Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE DIODES on page 7 97 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signal ing system s...

Page 313: ...ender Refer to CHECKING THE FUEL SENDER on page 7 102 Replace the fuel sender 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 7 103 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to C...

Page 314: ...FUEL INJECTION SYSTEM 7 27 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 315: ...ar cylinder injector 21 Front cylinder injector 22 O2 sensor 23 Engine temperature sensor 24 Crankshaft position sensor 25 Throttle position sensor 26 Intake air pressure sensor 27 Air temperature sensor 28 Speed sensor 29 Lean angle sensor 30 ISC idle speed control unit 32 Meter assembly 34 Multi function meter 36 Engine trouble warning light 44 Headlight relay 57 Right handlebar switch 59 Engine...

Page 316: ...de has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has b...

Page 317: ...type of malfunction When an abnormal signal 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 to operate or stop operating depending on the conditions The ECU takes fail safe actions in two ways one in which the sensor output is set to a prescri...

Page 318: ...FUEL INJECTION SYSTEM 7 31 EAS5S71040 TROUBLE SHOOTING CHART ...

Page 319: ... LCD 5 Set the engine stop switch to 6 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET switches TIP To decrease the selected diagnostic code number press the SELECT switch Press the SELECT switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT swit...

Page 320: ...hod Order Item components and probable cause Check or mainte nance job Sensor inspection procedure 1 Connection of crank shaft position sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault cod...

Page 321: ... Crankshaft position sensor malfunction Sensor inspection pro cedure Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 7 99 Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 12 Symptom Normal signals are not received from the crankshaft position sen sor Fail safe act...

Page 322: ...connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it s...

Page 323: ...ace the intake air pressure sensor Sensor inspection pro cedure Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 7 104 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 13 Symptom Open or short circuit of intake air pressure sensor lead Fail...

Page 324: ... is dam aged disconnected clogged twisted or bent Repair or replace the sensor hose Starting the engine and operating it at idle Fully close the throttle and check the fault recovery 2 Intake air pressure sen sor malfunction Check in the diagnos tic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101...

Page 325: ...dication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code ...

Page 326: ...ated If the indication is out side of range Replace the throttle position sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certai...

Page 327: ...ult code indication when the sid estand is retracted and extended No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON po...

Page 328: ...ct Replace the side stand switch Place the main switch to the ON position and check the fault code indication when the sid estand is retracted and extended No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Symptom Open or short circuit of ECU input line Blue Yellow lead Fail safe action Engine startup Impossible Riding Imp...

Page 329: ... and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault co...

Page 330: ...covered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 22 Symptom Open or short circuit of intake air temperature sensor lead Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No 05 Meter display 30 to 120 C During cold starting A temperature close to the ambient tempera ture is indicated During hot starting Ambient tempe...

Page 331: ...en sor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair r...

Page 332: ... method Make sure that the meter indication is close to the ambient tempera ture during cold starting Order Item components and probable cause Check or mainte nance job Sensor inspection procedure 1 Connection of engine temperature sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or r...

Page 333: ...step 4 Installation status of engine temperature sensor Check the mounting section for a loose or pinched mounting Make sure that the mounting position is correct Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step Fault code No 28 Symptom Open or short circuit of engine temperature sensor lead Fail...

Page 334: ...icated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 28 Symptom Open or short circuit of engine temperature sensor lead Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No 11 Meter display 30 to 120 C During cold starting A temperature close to the ambient tempera ture is indicated During hot starting The curr...

Page 335: ... cause Check or mainte nance job Sensor inspection procedure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch is first turned OFF 2 Sensor installation sta tus Check for a loose mounting pinched mounting or hard mounting Make sure that the mounting position is correct 3 Lean angle ...

Page 336: ...i mately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or replace the wire har ness Start and idle the engine for approxi mately 5 sec...

Page 337: ...o the On Off switching of ignition coil Order Item components and probable cause Check or mainte nance job Sensor inspection procedure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approxi matel...

Page 338: ...ly 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil malfunction Check the resistance of rear cylinder ignition coil Refer to CHECKING THE IGNITION COILS on page 7 98 Ignition coil inspection method Start and idle the engine for approxi mately 5 seconds Then check the fault code indication No fault code indicat...

Page 339: ...umber of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No 31 Meter display Each ignition coil turns On or Off 5 times per second The engine warning light flashes according to the On Off switching Checking method Make sure that the engine warning light flashes according to the On Off switching of ignition coil Order Item components and pro...

Page 340: ...e 6 6 Check the throttle cables Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 28 ISC valve returns to its original position by turning the main switch to ON and back OFF Reinstated if the engine idling speed is within specification after starting the engine 2 ISC valve installation status Check that the ISC unit coupler is not discon nected The ISC valve is stuck fully open if it does ...

Page 341: ... fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated R...

Page 342: ... harness Rotate the main switch to the OFF position first and then rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it secur...

Page 343: ...e the ECU Fault code No 41 Symptom Open or short circuit of lean angle sensor lead Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitor ing code No 08 Meter display The lean angle sensor value is indicated 0 to 5 0 V The vehicle is in a vertical position 0 4 1 4 V The vehicle is turned over 3 7 4 4 V Checking method Remove the lean angle sensor tilt the vehicle more than...

Page 344: ...n speed of the rear wheel increases This value is cumulative and is not reset each time the wheel is prevented from rotating Order Checkpoints Inspection method Locate the malfunction Check in the diagnostic mode Code No 07 Rotate the rear wheel and make sure that the indi cation value increases Malfunction Go to the Speed sensor system malfunction section below Check in the diagnostic mode Code N...

Page 345: ...e connection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Continuity of speed sensor leads Continuity of wire har ness Open or short circuit...

Page 346: ... connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Reconnect or repair the coupler 3 Continuity of wire har ness Open or short circuit Replace the wire har ness White Red Black Blue 4 Continuity of leads between neutral switch and relay unit coupler Open short circuit Replace the neutral switch Sky blue Sky blue 5 Neutral switch ...

Page 347: ...d check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approxi mately 5 seconds 2 Connection of fuel pump coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Connecti...

Page 348: ...d Replace the relay unit 7 ECU malfunction Replace the ECU Fault code No 43 Symptom Incorrect voltage supplied to the fuel injector and fuel pump Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No 50 Meter display The relay turns On or Off 5 times per second The engine warning light flashes according to the On Off switching Checking method Make sure that engine...

Page 349: ... con centration adjusted for cylinders 2 2 01 is indicated in Diagnostic mode Code No 60 EEP ROM data error for adjustment of CO concentration of cylin ders 1 Change the CO con centration of cylinders 1 and rewrite in EEP ROM After this adjustment is made the memory is not recovered when the main switch is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check ...

Page 350: ... Between the battery and main switch Red Red Between the main switch and ignition fuse Brown Blue Brown Blue Between the ignition fuse and ECU Red White Red White Start and idle the engine for approxi mately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Battery malfunction Check the battery volt age Refer to CHECKING AND...

Page 351: ... Item components and probable cause Check or mainte nance job Sensor inspection procedure 1 ECU malfunction Replace the ECU Place the main switch to the ON position Then check that no fault code indicated Fault code No 46 Symptom Incorrect voltage is supplied to the ECU Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No Meter display Checking method Order Item ...

Page 352: ...nd check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Continuity of ...

Page 353: ...heck each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Continuity of wire...

Page 354: ...ler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Continuit...

Page 355: ...e coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock ing Poor connection Connect it securely or repair replace the wire harness 3 Con...

Page 356: ...FUEL PUMP SYSTEM 7 69 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 357: ...YSTEM 7 70 1 Main switch 4 Main fuse 5 Battery 8 Fuel injection system fuse 10 Relay unit 12 Fuel pump relay 15 Fuel pump 16 ECU engine control unit 57 Right handlebar switch 59 Engine stop switch 69 Ignition fuse ...

Page 358: ... Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 7 95 Replace the relay unit 6 Check the fuel...

Page 359: ...FUEL PUMP SYSTEM 7 72 ...

Page 360: ...IMMOBILIZER SYSTEM 7 73 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 361: ...BILIZER SYSTEM 7 74 1 Main switch 4 Main fuse 5 Battery 9 Immobilizer unit 16 ECU engine control unit 32 Meter assembly 34 Multi function meter 41 Immobilizer indicator light 69 Ignition fuse 73 Backup fuse ...

Page 362: ...lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key for driving and to keep the code re regis tering key in a safe place Do n...

Page 363: ...egistering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Parts to be replaced Key registration requirement Main switch immo bilizer unit Standard key ECU Acces sory lock and key Main switch Immobi lizer unit Standard key is lost New standard key All keys have been lost including code re registering key Cod...

Page 364: ...urn the main switch to ON then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer system in...

Page 365: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the sec ond standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registe...

Page 366: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 7 92 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 87 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to IMMOBILIZER SYSTEM on page 7 73 Properly connect or repair the immobi lizer system wiring Check the condition of ...

Page 367: ...n con secutive attempts 2 Signal received from unregisteredstandard key 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or disconnected lead cable 1 Interference due to radio wave noise 2 Disconnected com munication harness...

Page 368: ...55 IMMOBILIZER UNIT Key code registration malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Undefinition code is received Noise interference or disconnected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace theECU Fault code Part Symptom Cause Action a Light on b Light off ...

Page 369: ...IMMOBILIZER SYSTEM 7 82 ...

Page 370: ...ELECTRICAL COMPONENTS 7 83 EAS27970 ELECTRICAL COMPONENTS ...

Page 371: ... sensor 2 Intake air pressure sensor 3 Rear cylinder ignition coil 4 Front cylinder ignition coil 5 Sub wire harness 6 ECU engine control unit 7 Turn signal relay 8 Speed sensor 9 Neutral switch 10 Oil level switch 11 Horn 12 Air temperature sensor ...

Page 372: ...ELECTRICAL COMPONENTS 7 85 ...

Page 373: ...lator 3 Fuse box 4 Headlight fuse 5 Backup fuse 6 Taillight fuse 7 Ignition fuse 8 Signaling system fuse 9 Main fuse 10 Battery 11 Lean angle sensor 12 Starter relay 13 Fuel injection system fuse 14 Relay unit 15 Headlight relay 16 Sidestand switch 17 Rear brake light switch ...

Page 374: ...ELECTRICAL COMPONENTS 7 87 EAS27980 CHECKING THE SWITCHES ...

Page 375: ...rake light switch 3 Front brake light switch 4 Reset switch 5 Select switch 6 Engine stop switch 7 Start switch 8 Hazard switch 9 Neutral switch 10 Sidestand switch 11 Pass switch 12 Dimmer switch 13 Turn signal switch 14 Horn switch 15 Clutch switch ...

Page 376: ... 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a g...

Page 377: ...g procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA3D81021 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bul...

Page 378: ... Fuse a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical cir...

Page 379: ...rformance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter ies The MF battery should be charged according to the appropriate charging method If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charg ing the battery TIP Since MF batteries are sealed it is n...

Page 380: ...n full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following i...

Page 381: ...r 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 ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the stan...

Page 382: ...2 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay 1 Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity betwe...

Page 383: ...place a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown b Turn the main switch to ON c Measure the turn signal relay output volt age Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input voltage DC 12 V Pocket tester 90890 03112 ...

Page 384: ...lack yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Neg...

Page 385: ... the spark gap until a misfire occurs EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28100 CHECKING THE IGNITION COILS The f...

Page 386: ...n sensor stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor resistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace Positive tester probe black red 1 Negative tester probe orange or gray red 2 Secondary coil resistanc...

Page 387: ...t tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the po...

Page 388: ...Out of specification Replace a Disconnect the horn connectors from the horn terminals b Connect the pocket tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Replace EAS3D81012 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the crankcase Positive tester probe white 2 Negative tester probe white 3 Charging voltage 14 V at ...

Page 389: ... Check Fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few sec onds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for three seconds in a repeated cycle malfunction detected in fuel sender or thermistor Replace the fuel sender Oil level switch Minimum level position resis...

Page 390: ...eel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28260 CHECKING THE ENGINE TEMPERATURE SENSOR 1 Remove Engine temperature sensor WARNING EWA14130 Handle the engine temperature sensor with special care Never subject the engine temperature sensor to strong ...

Page 391: ...sor adjust its angle properly Refer to THROTTLE BODIES on page 6 6 EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR The following procedure applies to the intake air pressure 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the intake air pressure sensor coupler as shown Tester positive probe black blue 1 Negative tester probe br...

Page 392: ...erature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the air temperature sensor terminal as shown b Immerse the air temperature sensor 1 in a container filled with water 2 TIP Make sure that the air temperature sensor ter minals do not get wet c Place a thermometer 3 in the water d Slowly heat the water and then let it cool down to the specified temperature e...

Page 393: ...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 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 394: ...nated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damag...

Page 395: ...ly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift ...

Page 396: ...lt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ri...

Page 397: ...h Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn ...

Page 398: ...45 Auxiliary light 46 Headlight 47 Horn 48 Turn signal relay 49 Left handlebar switch 50 Clutch switch 51 Turn signal switch 52 Horn switch 53 Pass switch 54 Dimmer switch 55 Front right turn signal light 56 Front left turn signal light 57 Right handlebar switch 58 Front brake light switch 59 Engine stop switch 60 Start switch 61 Select switch 62 Reset switch 63 Hazard switch 64 Rear right turn si...

Page 399: ......

Page 400: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 401: ...WIRING DIAGRAM XVS950A Y SCHEMA DE CABLAGE XVS950A Y SCHALTPLAN XVS950A Y SCHEMA ELETTRICO XVS950A Y DIAGRAMA DE CONEXIONES DE XVS950A Y ...

Page 402: ...WIRING DIAGRAM XVS950A Y SCHEMA DE CABLAGE XVS950A Y SCHALTPLAN XVS950A Y SCHEMA ELETTRICO XVS950A Y DIAGRAMA DE CONEXIONES DE XVS950A Y ...

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Yamaha Star XVS950A 2009, Service Manual

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