Yamaha STAR XVS95CE 1TP1 2014 Service Manual Download Page 1

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2014

SERVICE MANUAL

XVS95CE(C)

LIT-11616-27-30

1TP-28197-11

Summary of Contents for STAR XVS95CE 1TP1 2014

Page 1: ...2014 SERVICE MANUAL XVS95CE C LIT 11616 27 30 1TP 28197 11 ...

Page 2: ...by Yamaha Motor Corporation U S A First edition June 2013 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 27 30 ...

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

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

Page 5: ...ON 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 LOCTITE Engine oil Replace the part with a new one ...

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

Page 8: ......

Page 9: ... 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 RUBBER PARTS 1 7 BASIC SERVICE INFORMATION 1 8 QUICK FASTENERS 1 8 ELECTRICAL SYSTEM 1 9 SPECIAL TOOLS 1 13 ...

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

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

Page 12: ...e 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 deter mine 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 require...

Page 13: ...RIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 clock ODO If the fuel level warning light comes on the odometer display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case push the SELECT switch to change the display between the various tripme ter and odometer modes in the following o...

Page 14: ...osis device This model is equipped with a self diagnosis de vice for various electrical circuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indicate a fault code If the display indicates any fault codes note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 7 27 NOTICE ECA1TP1028 If the displa...

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 ...

Page 16: ... air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS1TP1072 RUBBER PARTS Check rubber parts for deterioration during i...

Page 17: ...tener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastene...

Page 18: ... a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then t...

Page 19: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 20: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 21: ...most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 kΩ a...

Page 22: ...takes 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 12 7 77 7 78 7 79 7 83 7 84 7 86 7 87 7 88 7 89 7 90 7 91 7 92 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 6 Vacuum gauge 90890 03094 Vacuummate YU 44456 3 ...

Page 23: ...4 58 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 58 4 59 Fork seal driver attachment ø41 90890 01381 Replacement 41 mm YM A5142 2 4 58 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Extension 90890 04136 5 1 Boots band installation tool 90890 01526 YM 01526 5 5 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 24: ...or 90890 04019 YM 04019 5 30 5 35 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 30 5 35 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 31 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 31 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 31 Tool name Tool No Illustra...

Page 25: ... 45 5 46 5 53 5 58 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 45 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 46 5 70 Universal clutch holder 90890 04086 YM 91042 5 53 5 56 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 63 6 11 7 88 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 26: ... Test harness TPS 3P 90890 03204 YU 03204 6 11 Yamaha diagnostic tool US 90890 03216 7 31 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 7 85 Test harness lean angle sensor 6P 90890 03209 YU 03209 7 87 Test harness S pressure sensor 3P 90890 03207 YU 03207 7 90 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 7 92 Tool name Tool No Illustration Reference pages ...

Page 27: ...12 TIGHTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 31 CABLE ROUTING 2 39 ...

Page 28: ...th rear suspensions equipped with gas cylinders XVS95CE 1TP3 CDN for models with rear suspensions not equipped with gas cylinders XVS95CE 2DX3 CDN for models with rear suspensions equipped with gas cylinders Dimensions Overall length 2290 mm 90 2 in Overall width 830 mm 32 7 in Overall height 1120 mm 44 1 in Seat height 690 mm 27 2 in Wheelbase 1570 mm 61 8 in Ground clearance 130 mm 5 12 in Minim...

Page 29: ...0 10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 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 Cartridge Oil pump Oil pump type Trochoid Inner rotor...

Page 30: ...ming chain Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside diameter 11 981 11 991 mm 0 4717 0 4721 in Limit 11 941 mm 0 4701 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 Valve valve seat valve guide Valve clearance cold Inta...

Page 31: ...6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide 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 spring 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 Li...

Page 32: ... 0 0012 0 0022 in Limit 0 15 mm 0 0059 in Diameter D 84 955 84 970 mm 3 3447 3 3453 in Height H 8 0 mm 0 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 Limit 0 07...

Page 33: ...th A 97 95 98 00 mm 3 856 3 858 in Runout limit C 0 020 mm 0 0008 in Big end side clearance D 0 320 0 474 mm 0 0126 0 0187 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 0 110 in Plate quantity 2 pcs F...

Page 34: ...r element Fuel pump Pump type Electrical Maximum consumption amperage 5 5 A Fuel injector Model quantity 1450 2 Resistance 12 0 Ω Throttle body Type quantity ACW35 1 ID mark 1TP1 00 CDN USA 1TP2 10 California Fuel line pressure at idling 220 300 kPa 2 20 3 00 kgf cm 31 3 42 7 psi Throttle position sensor Resistance 3 08 5 72 kΩ L B L Output voltage at idle 0 63 0 73 V Fuel injection sensor Cranksh...

Page 35: ...ENGINE SPECIFICATIONS 2 8 Intake vacuum 34 7 40 0 kPa 260 300 mmHg 10 2 11 8 inHg Oil temperature 60 0 70 0 C 140 00 158 00 F Throttle grip free play 4 0 6 0 mm 0 16 0 24 in ...

Page 36: ...odel BRIDGESTONE EXEDRA G721 Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 150 80B16M C 71H Manufacturer model BRIDGESTONE EXEDRA G722 Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 208 kg 0 459 lb USA California 0 90 kg 0 198 lb CDN Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 35 6 psi Loading condition 90 206 kg 198 454 lb ...

Page 37: ...n Caliper cylinder inside diameter 41 30 mm 1 63 in Specified brake fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 33 0 Center to lock angle right 33 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 mm 4 72 in Fork spring free length 322 2 mm 12 69 in Limit 315 8 mm 12 43 in Collar length 300 0 mm ...

Page 38: ...th gas cylinders 120 5 mm 4 74 in for models equipped with gas cylinders Spring rate K1 37 30 N mm 3 80 kgf mm 212 98 lbf in Spring rate K2 52 00 N mm 5 30 kgf mm 296 92 lbf in Spring stroke K1 42 0 mm 1 65 in Spring stroke K2 9 0 mm 0 35 in Enclosed gas air pressure STD 1200 kPa 12 0 kgf cm 170 7 psi Drive belt Drive belt slack on the sidestand 6 0 8 0 mm 0 24 0 31 in Drive belt slack on a suitab...

Page 39: ... Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Manufacturer GS YUASA Ten hour rate charging current 1 12 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 0 W 55 0 W 1 Tail brake light LED Front turn signal position light 12 V 23 0 W 8 0 W 2 Rear tu...

Page 40: ...ity 1 Maximum amperage 3 0 A Turn signal relay Relay type Semi transistor Built in self canceling device Yes Oil level switch Maximum level position resistance 484 536 Ω Minimum level position resistance 114 126 Ω Starting circuit cut off relay Coil resistance 162 0 198 0 Ω Headlight relay Coil resistance 96 Ω Fuel pump relay Coil resistance 162 198 Ω Fuses Main fuse 40 0 A Headlight fuse 20 0 A T...

Page 41: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0...

Page 42: ...bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Rear cylinder right cover bracket bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Shift arm pinch bolt M6 1 16 Nm 1 6 m kgf 12 ft lbf Tappet cover bolt M6 18 10 Nm 1 0 m kgf 7 2 ft lbf Fuel filter bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Camshaft retainer M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Engine temperature sensor M10 1 18 Nm 1 8 m kgf 13 ft lbf Front cylinder side cover ...

Page 43: ...f Muffler and muffler bracket bolt M10 2 35 Nm 3 5 m kgf 25 ft lbf Muffler protector 1 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector 2 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector inner M6 3 8 Nm 0 8 m kgf 5 8 ft lbf Muffler cap M6 5 8 Nm 0 8 m kgf 5 8 ft lbf Exhaust pipe nut M8 2 20 Nm 2 0 m kgf 14 ft lbf Exhaust pipe bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Exhaust pipe joint cover bolt M6 2 7...

Page 44: ... 0 40 m kgf 2 9 ft lbf Starter clutch bolt M8 3 24 Nm 2 4 m kgf 17 ft lbf Primary drive gear nut M18 1 100 Nm 10 m kgf 72 ft lbf Use a lock washer Clutch boss nut M20 1 125 Nm 12 5 m kgf 90 ft lbf Stake Clutch spring plate retainer bolt M6 6 8 Nm 0 8 m kgf 5 8 ft lbf Drive pulley nut M22 1 140 Nm 14 m kgf 100 ft lbf Stake Drive pulley housing bolt M8 5 24 Nm 2 4 m kgf 17 ft lbf Bearing retainer bo...

Page 45: ...ow 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 Throttle position sensor screw M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Inlet pipe assembly bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Pressure regulato...

Page 46: ...tighten the generator cover bolts in the order shown in the illus tration TIP Clutch cover bolt Temporally tighten the bolts a and b and then tighten the clutch cover bolts in the order shown in the illustration Bolt 1 13 15 12 Nm 1 2 m kgf 8 7 ft lbf Bolt 14 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 47: ...Ignition coil bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Ignition coil bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable locknut crankcase side M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Cable and wire harness guide bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Right handlebar switch lead hold er bolt ...

Page 48: ...torque M25 1 52 Nm 5 2 m kgf 38 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 M10 4 23 Nm 2 3 m kgf 17 ft lbf Front fork damper rod bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Front fork cap bolt M38 2 23 Nm 2 3 m kgf 17 ft lbf Front brake master cylinder res ervoir cap screw M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Lower handlebar holder ...

Page 49: ...4 28 Nm 2 8 m kgf 20 ft lbf Rear fender bracket and frame bolt M10 4 65 Nm 6 5 m kgf 47 ft lbf Tail brake light assembly and rear fender nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate bracket and rear fender bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate light nut M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Mudguard and rear fender nut M6 2 8 5 Nm 0 85 m kgf 6 1 ft lbf Mudguard and rear fender bolt M6 ...

Page 50: ...t bracket bolt For Canada M8 2 20 Nm 2 0 m kgf 14 ft lbf Passenger seat guide bolt For Canada M8 2 20 Nm 2 0 m kgf 14 ft lbf Sidestand bracket bolt M10 2 48 Nm 4 8 m kgf 35 ft lbf Sidestand switch bolt M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Sidestand nut M10 1 64 Nm 6 4 m kgf 46 ft lbf Rear brake master cylinder bracket bolt M8 2 23 Nm 2 3 m kgf 17 ft lbf Rider footrest cover nut M6 4 7 Nm 0 7 m kgf 5 ...

Page 51: ...n it to 59 Nm 5 9 m kgf 43 ft lbf 2 In the order pinch bolt 1 pinch bolt 2 pinch bolt 1 tighten each bolt to 20 Nm 2 0 m kgf 14 ft lbf without performing temporary tightening 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 ...

Page 52: ...filter cartridge union bolt Crankcase stud bolts Starter clutch idle 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 shaft Starter clutch idle gear 2 Primary driven gear inner surface and collar Clutch pull rod Oil pump drive sprocket inner surface Clutch thrust washers Clutch boss nut an...

Page 53: ...ATION POINTS AND LUBRICANT TYPES 2 26 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankcase breather pipe Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 54: ...pivoting point and metal to metal moving parts Footrest assembly pivoting point Throttle grip tube guide inner 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 Pivot shaft outer surface Re...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 57: ... 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 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil filter cartridge 2 Oil delivery pipe 2 3 Relief valve assembly ...

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

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

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil drain bolt 2 Crankshaft ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Drive axle 2 Oil delivery pipe 1 3 Main axle 4 Oil delivery pipe 2 5 Oil pump assembly 6 Oil strainer ...

Page 66: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING Handlebar top and front view 1 2 3 4 5 6 6 A B C D G F F 5 G E 2 3 2 3 4 7 8 9 1 H I J K L 10 A D 5 6 M N O ...

Page 67: ... with the plastic band at the bend in the handlebar E Fasten the left handlebar switch lead with the plastic band Align the plastic band with the locknut F Point the end of the plastic band downward G Face the buckle of the plastic band forward H Route the right handlebar switch lead under the handlebar I Route the left handlebar switch lead under the handlebar J Route the clutch cable to the fron...

Page 68: ...CABLE ROUTING 2 41 Headlight 3 2 2 1 A D B 1 4 5 6 7 7 8 8 9 9 10 11 C 12 12 12 13 ...

Page 69: ...embly lead 11 Right handlebar switch lead 12 Wire harness 13 Left handlebar switch lead A Fasten the headlight lead and intake air temperature sensor sub wire harness with the holder Be sure to position the holder inside the headlight assembly B Fasten the intake air temperature sensor sub wire harness and accessory light lead with the holder C Route the wire harness through the guide D Insert the...

Page 70: ...CABLE ROUTING 2 43 Steering head cable right side view G 4 5 H H 6 I J K L 7 M 1 2 A B C D 3 E F 7 U V W 9 X Y Z S T 1 5 AE AD AJ AA AF AB AC 14 P O N AG 6 AH AI R 10 10 8 Q 13 12 1 5 11 ...

Page 71: ...he projection on the band into the hole in the frame and then fasten the clutch cable and wire harness with the band making sure to point the end of the band downward T Fasten the wire harness and clutch cable with the plastic band Position the buckle of the plastic band toward the frame so that it does not protrude to the outside of the wire harness and place the end of the band between the frame...

Page 72: ...CABLE ROUTING 2 45 Clutch cable right side view 3 4 H A B C D E G F I I 1 2 5 6 7 8 5 5 10 11 11 9 3 4 ...

Page 73: ...t the projection on the starter motor lead holder into the hole in the engine bracket rear lower side E Fasten the brake fluid reservoir hose rear brake light switch lead and O2 sensor lead with the plastic band Face the buckle of the plastic band upward with the end pointing downward F Insert the projection on the wire harness holder into the hole in the battery box G Insert the projection on the...

Page 74: ...CABLE ROUTING 2 47 Frame inner side view A 1 2 B 3 4 5 C D E 6 F G H I J 7 8 9 10 K 11 ...

Page 75: ... sensor D To the starter relay E Route the starter motor lead to the front of the frame cross member F Route the starter motor lead and rear brake light switch lead under the engine bracket rear lower side G Route the rear brake light switch lead under the mounting position for the starter motor lead on the engine bracket rear lower side H Insert the projection on the starter motor lead holder int...

Page 76: ...CABLE ROUTING 2 49 Rear brake hose right side view C G H E F C D A B 1 1 2 3 3 3 3 I J K L ...

Page 77: ...tor bracket D Fasten the brake fluid reservoir hose at the white paint mark E Route the brake fluid reservoir hose to the outside of the engine bracket rear lower side F Point the ends of the hose clamp upward G Install the brake fluid reservoir hose with its white paint mark facing upward H Route the rear brake hose to the inside of the engine bracket rear lower side I Route the brake fluid reser...

Page 78: ...CABLE ROUTING 2 51 Front brake hose front and left side view 2 A 1 1 B D 1 1 3 3 3 3 3 C ...

Page 79: ...se through the cable guide B 20 40 C Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder D Fasten the front brake hose with the holder making sure that the paint mark on the hose is aligned with the open ends of the holder ...

Page 80: ...CABLE ROUTING 2 53 Steering head left side view A B C 1 2 5 6 7 8 9 10 D E F G H 11 12 I J K L M N 3 4 ...

Page 81: ...d around the protective sleeves of the leads not the leads themselves F Fasten the main switch couplers with the plastic band Be sure to position the main switch coupler red above the main switch coupler white G Connect the rear cylinder injector coupler which has white tape on the lead to rear cylinder injector H After connecting the engine temperature sensor coupler cover the coupler with the co...

Page 82: ...CABLE ROUTING 2 55 Spark plug lead B A 2 2 1 1 C F 3 4 3 5 6 7 8 9 10 11 10 D 11 8 E ...

Page 83: ...linder spark plug lead with the holder B Fasten the fuel hose hose joint to pressure regulator with the holder C Fasten the hose protector of the fuel tank breather hose with the hose holder Make sure that the fuel tank breather hose contacts the fuel tank bracket D Position the buckle of the plastic band below the frame and place the end of the band to the inside of the rear cylinder head cover E...

Page 84: ...CABLE ROUTING 2 57 Electrical components tray left side view 4 6 6 8 7 14 15 P S P Q 1 2 3 4 4 5 6 7 12 3 1 1 3 3 4 2 3 20 20 A C D E F G H I J K L M N O U W X V B B R 8 9 10 11 13 16 17 18 T 19 ...

Page 85: ...tion on the coupler cover into the hole in the frame L Fasten the oil level switch lead and sidestand switch lead with the holder Position the holder between the sidestand switch coupler and the sidestand switch lead holder M Install the sidestand switch lead holder at the location shown N Fasten the oil level switch lead to the frame with a plastic locking tie O Point the end of the plastic locki...

Page 86: ...CABLE ROUTING 2 59 Rectifier regulator rear view 1 2 3 4 5 6 8 9 10 10 11 A B C 14 D 12 F G H 15 16 I 7 E 13 ...

Page 87: ...rt the projection the stator motor lead holder into the hole in the engine bracket rear lower bracket B Insert the projection on the wire harness holder into the hole in the battery box C Insert the projection on the tail sub wire harness holder into the hole in the battery box D To the wire harness E To the stator coil F Secure the holder by inserting the projection on the holder into the hole in...

Page 88: ...CABLE ROUTING 2 61 Rear fender top and left view 1 2 3 4 4 A B 6 2 5 5 1 1 1 7 8 C C C D E H F G 3 9 10 11 ...

Page 89: ...il sub wire harness through the guides and then secure the lead by bending the guides around the lead B Align the white tape on the tail sub wire harness with the guide C Install each coupler so that both ends of the female section of the coupler are protruding past the edges of the holder D To the holder on the rear fender E To the rear left turn signal light F To the license plate light G Route ...

Page 90: ...CABLE ROUTING 2 63 Fuel tank 5 K 1 M H 8 8 R 10 10 3 7 7 7 9 N O P Q I H J J 2 3 4 5 6 D E F F G L L A B C 1 2 11 ...

Page 91: ...ressure regulator completely onto the hose fitting of the pressure regulator making sure that the yellow paint mark on the hose is facing outward J Align the ends of the hose clamp with the yellow paint mark on the fuel hose hose joint to pressure regulator Make sure not to install the hose clamp on the raised portion of the hose fitting K Install the fuel sender so that the fuel sender lead is ro...

Page 92: ...CABLE ROUTING 2 65 Fuel tank breather hose except for California left and rear view D 1 A 1 1 2 2 B B 3 3 C ...

Page 93: ...ose from rollover valve A Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box B 2 8 mm 0 08 0 31 in C Install the fuel tank breather hose hose joint to rollover valve with its white paint mark facing rearward D Route the fuel tank breather hose hose joint to rollover valve through the guide ...

Page 94: ...CABLE ROUTING 2 67 Canister for California left and rear view 1 1 1 2 2 3 4 3 4 5 A B C C C D E F G H ...

Page 95: ...ox B Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box C 2 8 mm 0 08 0 31 in D To the throttle body E Install the fuel tank breather hose hose joint to rollover valve with its white paint mark facing rearward F Route the canister purge hose to the rear of the frame cross member G Install the fuel tank breather hose rollover valve to canister with its yel...

Page 96: ...CABLE ROUTING 2 69 Fuel tank breather hose top and right view B 5 1 2 3 4 A B C ...

Page 97: ...l tank breather hose hose joint to rollover valve 5 Canister for California A Route the canister purge hose along the fuel tank breather hose hose joint to rollover valve for California B Point the ends of the hose clamp to the right C Install the intake air pressure hose with its white paint mark facing to the right ...

Page 98: ...CABLE ROUTING 2 71 Canister top and right view 1 B D E F C 3 2 2 A ...

Page 99: ...pletely onto the hose fitting making sure that the yellow paint mark on the hose is facing upward C 1 2 mm 0 04 0 08 in D Install the canister purge hose completely onto the hose fitting making sure that the blue paint mark on the hose is facing upward for California E 2 4 mm 0 08 0 16 in F Align the hose clamp with the blue paint mark on the canister purge hose and point the ends of the clamp for...

Page 100: ...CABLE ROUTING 2 73 Crankcase breather hose left side view H 1 A A B 1 C 2 D F G I 3 E ...

Page 101: ...int the ends of the hose clamp rearward E Align the hose clamp with the yellow paint mark on the crankcase breather hose F Install the crankcase breather hose completely onto the hose joint making sure that the yellow paint mark on the hose is facing upward G Yellow paint mark H Align the hose clamp with the white paint mark on the crankcase breather hose I Install the crankcase breather hose onto...

Page 102: ...CABLE ROUTING 2 75 ...

Page 103: ...S 3 14 CHECKING THE TIRES 3 14 CHECKING THE WHEEL BEARINGS 3 15 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 3 16 CHECKING THE DRIVE BELT 3 16 ADJUSTING THE DRIVE BELT SLACK 3 16 CHECKING AND ADJUSTING THE STEERING HEAD 3 18 LUBRICATING THE STEERING BEARINGS 3 19 CHECKING THE CHASSIS FASTENERS 3 19 LUBRICATING THE BRAKE LEVER 3 19 LUBRICATING THE BRAKE PEDAL 3 19 LUBRICATING THE CLUTCH LEVER 3 19 LU...

Page 104: ...LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE 3 25 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 26 ADJUSTING THE HEADLIGHT BEAM 3 26 REPLACING THE HEADLIGHT BULB 3 26 ...

Page 105: ......

Page 106: ...IP From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months Items marked with an asterisk require special tools data and technical skills have a Yamaha dealer perform the service No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi...

Page 107: ... if necessary 9 Wheel bearings Check bearings for smooth operation Replace if necessary 10 Swingarm pivot bearings Check operation and for ex cessive play Moderately repack with lithi um soap based grease Every 32000 mi 50000 km 11 Drive belt Check belt condition Replace if damaged Check belt tension Adjust if necessary Every 2500 mi 4000 km 12 Steering bearings Check bearing assemblies for loosen...

Page 108: ... brake fluid Replace the brake hoses every four years and if cracked or damaged 21 Shock absorber assemblies Check operation and for oil leakage Replace if necessary 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 Apply Yamaha chain and ca ble lube or engine oil thor oughly 26 Throttle grip C...

Page 109: ...event it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug TIP Before installi...

Page 110: ... Spark plugs Refer to CAMSHAFTS on page 5 16 8 Remove Damper cover Generator cover damper Timing mark accessing screw Crankshaft end accessing screw Refer to GENERATOR AND STARTER CLUTCH on page 5 42 9 Remove Front cylinder tappet covers 1 10 Remove Fuel filter bracket 1 Rear cylinder tappet covers 2 11 Measure Valve clearance Out of specification Adjust Front cylinder a Turn the crankshaft counte...

Page 111: ...Loosen the locknuts 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 speci fied 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...

Page 112: ...Refer to FUEL TANK on page 6 1 Air duct Refer to BELT DRIVE on page 4 70 Air filter case 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 filter element Throttle body joints Fuel hoses Exhaust system Canister purge hoses for California Breather hoses 1 Stand the veh...

Page 113: ...ure c If the vacuum pressure of the throttle body with the lower pressure is out of specification adjust it to specification first and then syn chronize the throttle bodies TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn the screw in fully and then turn it out 1 1 4 turns Then syn chronize ...

Page 114: ...rque Exhaust pipe joint nuts 6 Exhaust pipe nuts 7 Exhaust pipe bolts 8 Muffler bracket and frame bolt 9 Muffler bracket and Engine bracket rear low er side bolts 10 Muffler and exhaust bolt 11 Muffler bracket and muffler bolts 12 EAS1TP1067 CHECKING THE CANISTER for California 1 Check Canister 1 Canister purge hose 2 Fuel tank breather overflow hose 3 Cracks damage Replace EAS20960 REPLACING THE ...

Page 115: ...l Check the clutch system Refer to CLUTCH on page 5 48 WARNING EWA1TP1010 Before checking the clutch operation check the brake system and make sure that the brake is operating at all times during the check up While checking the clutch opera tion do not rev up the engine a Place the vehicle on a level surface and start the engine b Grab the clutch lever and make sure that you can shift the gear smo...

Page 116: ...e brakes are operating fully EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level WARNING EWA1TP1021 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteri...

Page 117: ...s 1 Operate the brake 2 Check Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 35 EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA13100 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP...

Page 118: ... 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 specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation 3 Install Brake fluid reservoir cover EAS21280 CHECKING THE FRONT B...

Page 119: ...erature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire trea...

Page 120: ...d of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA1TP1012 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km 60 mi should be traveled at normal speed be fore any high speed riding is done TIP For tires ...

Page 121: ...to run but moni tor condition Bevel wear outboard edge only H OK to run but monitor condition Refer to BELT DRIVE on page 4 70 3 Install Drive belt upper guard and lower guard Refer to REAR WHEEL on page 4 16 EAS21430 ADJUSTING THE DRIVE BELT SLACK TIP The drive belt slack must be checked at the tight est point on the belt NOTICE ECA14950 A drive belt that is too tight will overload the engine and...

Page 122: ...drive belt adjusting bolts 3 in di rection a or b until the specified drive belt slack is obtained TIP Using the alignment marks 4 on each side of the swingarm make sure that both belt pullers are in the same position for proper wheel align ment d Tighten the drive belt adjusting bolt locknuts to specification e Tighten the rear wheel axle nut to specifica tion 6 Install Muffler Refer to ENGINE RE...

Page 123: ...it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 61 e Install the rubber washer 3 f Install the upper ring nut 2 TIP In...

Page 124: ...nd 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 Sidestand vertical movement A Free play is noticeable Replace the defec tive part s Sidestand axial movement B Unsmooth operation Replace the defec tive part s a Tighten the sidestand nut 1 ...

Page 125: ...everal times Unsmooth operation Replace rear shock absorber assembly Refer to SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES on page 4 65 EAS1TP1073 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES for models not equipped with gas cylinders The following procedure applies to both of the rear shock absorber assemblies WARNING EWA1TP1013 Securely support the vehicle so that there is no danger of it falling...

Page 126: ...ed position on the adjusting ring with the stopper 2 EAS20750 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the suitable stand Make sure that the vehicle is upright 2 Let the engine idle for a few minutes and then turn it off 3 Remove Dipstick 1 4 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level...

Page 127: ...AS20780 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Dipstick 1 along with the O ring Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filte...

Page 128: ...ght cover bracket Refer to ENGINE REMOVAL on page 5 3 14 Check Engine oil pressure a Slightly loosen the front cylinder oil check bolt 1 and rear cylinder oil check bolt 2 b Start the engine and keep it idling until engine oil starts to seep from the oil check bolts If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil fil...

Page 129: ...roper time EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate or replace TIP Hold the ...

Page 130: ...pecified throttle grip free play is ob tained c Tighten the locknut TIP If the specified throttle grip free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle grip free play is ob tained c Tighten the locknut 6 Install Fuel tank R...

Page 131: ... vertically a Turn the adjusting screw 1 with a screw driver in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 with a screw driver in direction a or b EAS21790 REPLACING THE HEADLIGHT BULB 1 Remove Headlight lens unit 1 2 Disconnect Headlight coupler 2 3 Remove Headlight bulb cover 3 4 Detach Headlight bulb holder 4 5 Remove Headlight bulb 5 Direction a Headligh...

Page 132: ...ing 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 7 Attach Headlight bulb holder 8 Install Bulb cover TIP When installing the headlight bulb cover make sure the TOP...

Page 133: ...THE REAR WHEEL DRIVE HUB 4 20 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 20 ASSEMBLING THE REAR WHEEL 4 21 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 21 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 21 FRONT BRAKE 4 23 INTRODUCTION 4 28 CHECKING THE FRONT BRAKE DISC 4 28 REPLACING THE FRONT BRAKE PADS 4 29 REMOVING THE FRONT BRAKE CALIPER 4 30 DISASSEMBLING THE FRONT BRAKE CALIPER 4 30 CHECKING T...

Page 134: ...4 56 DISASSEMBLING THE FRONT FORK LEGS 4 56 CHECKING THE FRONT FORK LEGS 4 57 ASSEMBLING THE FRONT FORK LEGS 4 57 INSTALLING THE FRONT FORK LEGS 4 60 STEERING HEAD 4 61 REMOVING THE LOWER BRACKET 4 63 CHECKING THE STEERING HEAD 4 63 INSTALLING THE STEERING HEAD 4 63 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES 4 65 REMOVING THE SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES 4 67 CHECKING THE SWINGARM ...

Page 135: ......

Page 136: ...1 For Canada 5 Battery cover holder 1 6 Battery cover 1 7 Brake fluid reservoir cover 1 8 Brake fluid reservoir 1 9 Right side cover 1 For installation reverse the removal proce dure LT 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 1 3 4 2 9 6 5 7 8 ...

Page 137: ...seat 1 TIP Insert the projection a on the rear of the seat into the seat holder b as shown While pushing the front of the seat down so that there is no space between the rubber dampers c and the frame d tighten the bolt T R Rider seat bolt 16 Nm 1 6 m kgf 12 ft lbf b a 1 c d ...

Page 138: ...Battery band 2 5 ECU bracket 1 6 Negative battery lead 1 Disconnect 7 Positive battery lead 1 Disconnect 8 Battery 1 9 Tool box band 1 10 Tool box 1 11 Relay unit 1 12 Turn signal relay 1 13 Head light relay 1 14 Fuse box 1 15 Main fuse 1 16 Starter relay coupler 1 Disconnect 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R FWD 10 1 9 2 2 3 5 7 6 8 8 4 4 11 11 12 12 14 14 15 15 13...

Page 139: ...tarter relay 1 Disconnect 20 Starter relay 1 For installation reverse the removal proce dure Removing the battery and relays Order Job Parts to remove Q ty Remarks 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R FWD 10 1 9 2 2 3 5 7 6 8 8 4 4 11 11 12 12 14 14 15 15 13 13 19 17 16 18 20 20 ...

Page 140: ...GENERAL CHASSIS 4 5 EAS1TP1065 INSTALLING THE TOOL BOX 1 Install Tool box 1 TIP Install the tool box with the INSIDE mark a facing inward 1 a ...

Page 141: ...y 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 New New 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 4 2 Nm 0 42 m kgf 3 0 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 2 1 4 4 ...

Page 142: ... fender bracket 1 11 Rear left turn signal light coupler 1 Disconnect Refer to CABLE ROUTING on page 2 39 12 Rear right turn signal light coupler 1 Disconnect Refer to CABLE ROUTING on page 2 39 13 Rear left turn signal light 1 14 Rear right turn signal light 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m ...

Page 143: ...move Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 8 5 Nm 0 85 m k...

Page 144: ... 2 Headlight coupler 1 Disconnect 3 Intake air temperature sensor coupler 1 4 Headlight body 1 For installation reverse the removal proce dure 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 2 1 4 ...

Page 145: ...nd 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 6 3 1 2 6 5 5 4 LT 20 Nm 2 0 m kgf 14 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 146: ...FRONT WHEEL 4 11 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 New New New ...

Page 147: ... 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 surface c Remove the wheel bearings 3 with a gener al 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 ax le 2 Check Tir...

Page 148: ... the 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 fro...

Page 149: ...eps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC 1 Install Front brake disc TIP Tighten the brake disc bolts in stages and in a crisscross pattern Install the br...

Page 150: ...right side and tighten it to 59 Nm 5 9 m kgf 43 ft lbf b In the order pinch bolt 1 pinch bolt 2 pinch bolt 1 tighten each bolt to 20 Nm 2 0 m kgf 14 ft lbf without performing temporary tightening 5 Install Front brake caliper WARNING EWA1TP1001 Make sure the brake hose is routed properly T R 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 T R Front ...

Page 151: ...RAL CHASSIS on page 4 1 1 Rear brake caliper 1 2 Drive belt upper guard 1 3 Drive belt adjusting bolt locknut 2 Loosen 4 Drive belt adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1 7 Rear wheel axle 1 8 Drive belt puller 2 9 Rear wheel 1 10 Collar left 1 LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 150 Nm 1...

Page 152: ...reverse the removal proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 150 Nm 15 m kgf 108 ft lbf T R 1 11 12 6 5 3 4 3 4 2 9 10 8 8 7 ...

Page 153: ...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 Collar 1 11 Rear wheel drive hub damper 6 12 Rear wheel 1 For installation reverse the removal proce dure LS LT LS New New 23 Nm 2 3 m kgf 17 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R 10 11 12 6 7 8 5 9 4 3 1 6 5 2 ...

Page 154: ...REAR WHEEL 4 19 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Bearing 1 2 Oil seal 1 3 Bearing 1 4 Spacer 1 For assembly reverse the disassembly pro cedure LS New New New 4 1 3 2 ...

Page 155: ...o CHECKING THE FRONT WHEEL on page 4 12 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 14 and CHECKING THE WHEELS on page 3 14 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 12 EAS1TP1014 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace EAS22110 CHECKING THE REAR WHEEL...

Page 156: ... 2 Install Rear brake disc TIP Apply locking agent LOCTITE to the threads of the brake disc bolts Install the brake disc so that the chamfered portions of the bolt holes a face away from the hub 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 41 4 Install Rear brake caliper bracket 1 Rear wheel axle Washer R...

Page 157: ...n Rear wheel axle nut 7 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly T R Rear wheel axle nut 150 Nm 15 m kgf 108 ft lbf T R Rear brake caliper retaining bolt 27 Nm 2 7 m kgf 20 ft lbf ...

Page 158: ...ont brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 2 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal proce dure 6 6 3 4 3 4 5 1 1 2 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R S ...

Page 159: ...oir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake light switch 1 8 Front brake hose union bolt 1 9 Brake hose gasket 2 10 Front brake hose 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 For installation reverse the removal proce dure 7 6 1 2 3 4 5 8 9 10 11 12 New S 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 Nm 0 1 m kgf 0 7 ft Ibf ...

Page 160: ... 25 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 BF New 1 2 S S BF ...

Page 161: ...r to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Front brake hose union bolt 1 2 Brake hose gasket 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 30 Nm 3 0 m kgf 22 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R New 1 2 3 5 4 4 ...

Page 162: ... pad shim 2 4 Brake pad spring 1 5 Brake pad support 2 6 Brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 10 6 5 7 9 8 7 9 8 2 4 3 3 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R BF S S S S S S New New New New ...

Page 163: ... 10 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 deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d...

Page 164: ...e pad shims brake pad supports and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed 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 pad shims a new brake pad supports new brake pads and a new...

Page 165: ...IPER 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 Brake caliper piston dust seals 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA1TP1002 Cover the brake caliper pistons with a rag Be careful not to get injured when the pis ton are expelled from the brake caliper Never try to pry out the brake caliper pis ton b ...

Page 166: ...rake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brake caliper 1 temporarily Brake hose gaskets Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 39 NOTICE ECA14170 When installing the brake hose onto the ...

Page 167: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose ...

Page 168: ...thin the angle shown in the illustra tion 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 specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other br...

Page 169: ...ke system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 a ...

Page 170: ...s to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Rear brake pad shim 2 5 Rear brake pad spring 2 For installation reverse the removal proce dure 1 1 2 5 4 3 4 5 S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R ...

Page 171: ... 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 holder 1 8 Rear brake hose union bolt 1 9 Brake hose gasket 2 10 Rear brake hose 1 11 Right rider footrest assembly 1 12 Rear brake master cylinder 1 13 Rear brake light switch coupler 1 Disconnect New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm ...

Page 172: ...ce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 10 11 8 9 4 1 7 5 3 2 6 13 14 12 6 ...

Page 173: ...der Job Parts to remove Q ty Remarks 1 Rear brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Brake hose joint 1 4 Bush 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF S New 2 New 4 3 1 5 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 174: ... to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Rear brake hose union bolt 1 2 Brake hose gasket 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 4 4 5 1 2 3 S New 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 175: ...Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper bracket 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad spring 2 For assembly reverse the disassembly pro cedure BF S New 6 Nm 0 6 m kgf 4 3 ft Ibf T R 3 New 2 1 4 7 6 8 5 8 6 7 ...

Page 176: ... 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 28 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 28 5 Adjust Brake disc defle...

Page 177: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 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 Brake hose g...

Page 178: ...ts should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake ca...

Page 179: ... lock NOTICE 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 12 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal o...

Page 180: ... master cylinder kit Rear brake master cylinder joint TIP The rear brake master cylinder joint installation length a should be 101 8 mm 4 01 in EAS22750 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Rear brake light switch 1 TIP The rear brake light switch installation length a should be 8 5 mm 0 33 in Install the rear brake light switch spring 2 as shown in the illustration 2 Install Brake ...

Page 181: ...brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 6 Check Brake fluid level Below the minimum level mark a Add the speci...

Page 182: ...ight handlebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Clutch switch coupler 1 Disconnect 9 Left handlebar switch 1 10 Handlebar grip 1 11 Clutch cable 1 Disconnect 12 Clutch lever 1 13 Clutch switch 1 LT LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 32 Nm 3 2 m...

Page 183: ...the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks LT LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 1 11 12 14 13 19 18 1...

Page 184: ...of it falling over 2 Install Handlebar 1 Upper handlebar holders 2 NOTICE ECA1TP1010 First tighten the bolts on the upper side of the upper handlebar holder and then on the lower 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 the punch mark a on the handlebar 3 I...

Page 185: ...andlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be less than 3 mm 0 12 in of clearance a between the handlebar grip and left handlebar switch 8 Install Throttle cables 1 to the right handlebar switch 2 9 Install Right handlebar switch 1 TIP Align the projection a on the righ...

Page 186: ...h mark a on the handle bar First tighten the upper bolt then the lower bolt 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 10 12 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 24 T R Front brake master cylinder hold er bolt 10 Nm 1 0 m kgf 7 2 ft lbf Clutch lever free play 5 0 10 0 mm 0 20 0 39 in Throttle grip free ...

Page 187: ...ront turn signal position light pinch bolt 1 Loosen 9 Lower bracket pinch bolt 2 Loosen 10 Front fork leg 1 11 Air temperature sensor bracket 1 Left side only 12 Air temperature sensor 1 Left side only 13 Front turn signal position light 1 1 2 5 4 3 1 10 9 9 6 14 13 12 11 8 7 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20...

Page 188: ...emarks 1 2 5 4 3 1 10 9 9 6 14 13 12 11 8 7 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 189: ...t fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 11 Damper rod 1 12 Damper rod ring 1 13 Rebound spring 1 14 Inner tube 1 15 Oil seal 1 16 Washer 1 LT LS LS LS New 7 New 8 New 15 16 1 New 17 20 New 10 9 New 18 19 14 New 3 4 5 6 12 11 13 2 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 190: ...flow stopper 1 20 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks LT LS LS LS New 7 New 8 New 15 16 1 New 17 20 New 10 9 New 18 19 14 New 3 4 5 6 12 11 13 2 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 191: ...while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Front fork damper rod bolt 1 Copper washer TIP While holding the damper rod with the damper rod holder 2 and T handle 3 loosen the front fork damper rod bolt 4 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper...

Page 192: ...the front fork leg do not allow any foreign ma terial 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 ...

Page 193: ...p 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 Recommended oil Yamaha fork oil 10WT T R Front fork damper rod bolt 30 Nm 3 0 m kgf 22 ft lbf LOCTITE Damper rod holder 22 ...

Page 194: ... 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 Fork spring Spring seat Spacer Front fork cap bolt along with the O ring Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 3 2 1 New New New ...

Page 195: ... coupler into the slot a in the front turn signal position light 2 Install Front fork leg 1 Temporarily tighten the lower bracket pinch bolts TIP Make sure the inner tube end is flush with the top of the upper bracket 3 Tighten Lower bracket pinch bolts TIP Tighten the lower bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts 4 Ti...

Page 196: ... FRONT FORK on page 4 52 1 Headlight bracket 1 2 Front brake hose holder 1 3 Steering stem nut 1 4 Washer 1 5 Upper bracket 1 6 Lock washer 1 7 Upper ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lower bracket 1 11 Upper bearing cover 1 12 Upper bearing inner race 1 10 9 8 7 6 11 12 17 13 17 14 16 15 4 3 5 2 1 18 LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8...

Page 197: ...ap 1 For installation reverse the removal proce dure Removing the upper bracket and lower bracket Order Job Parts to remove Q ty Remarks 10 9 8 7 6 11 12 17 13 17 14 16 15 4 3 5 2 1 18 LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf T R 110 Nm 11 m kgf 80 ft lbf T R 19 Nm 1 9 m kgf 14 ft Ibf T R ...

Page 198: ...m the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es NOTICE 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 steering head is disassembled replace the...

Page 199: ...cket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 52 TIP Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut 7 Install Front brake hose holder 1 Headlight bracket TIP Align the projection a on the front brake hose holder with the hole b in the lower bracket T R Steering stem nut 11...

Page 200: ... Drive belt lower guard 1 2 Rear brake hose guide 1 3 Rear shock absorber assembly 2 4 Pivot shaft cover 2 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Collar 2 9 Dust seal 2 10 Spacer 2 11 Dust seal 2 LS LS LS New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft...

Page 201: ...roce dure Removing the swingarm and rear shock absorber assemblies Order Job Parts to remove Q ty Remarks LS LS LS New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 85 Nm 8 5 m kgf 61 ft Ibf T R 2 9 3 12 12 11 11 4 6 10 7 4 5 9 8 10 8 1 3 A B A 3 ...

Page 202: ...up or down e If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings collars and dust seals EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust seals Spacers Collars Bearings ...

Page 203: ...protection to prevent eye damage from released gas or metal chips EAS1TP1075 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Oil leaks Replace the rear shock absorber assembly for models not equipped with gas cylinders Gas leaks oil leaks Replace the rear shock absorber assembly for models equippe...

Page 204: ...pped with gas cylinders 5 Tighten Rear shock absorber assembly upper bolt 6 Tighten Rear shock absorber assembly lower nut 7 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 16 T R Pivot shaft nut 85 Nm 8 5 m kgf 61 ft lbf T R Rear shock absorber assembly upper bolt 23 Nm 2 3 m kgf 17 ft lbf T R Rear shock absorber assembly lower nut 30 Nm 3 0 m kgf 22 ft lbf 1 a ...

Page 205: ...OCK ABSORBER ASSEMBLIES on page 4 65 1 Air duct 1 2 Drive pulley cover 1 3 Drive belt 1 4 Speed sensor coupler 1 Disconnect 5 Speed sensor 1 6 Speed sensor bracket 1 7 Drive pulley nut 1 8 Washer 1 9 Drive pulley 1 For installation reverse the removal proce dure 140 Nm 14 m kgf 100 ft lbf T R 6 5 1 2 3 7 8 9 4 3 New LS New LT LT L T LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 206: ...irt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check Drive belt NOTICE ECA1TP1030 To protect the drive belt from damage han dle 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 Re...

Page 207: ...ts a in the drive axle When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move 4 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 16 T R Drive pulley nut 140 Nm 14 m kgf 100 ft lbf LOCTITE a ...

Page 208: ...BELT DRIVE 4 73 ...

Page 209: ...THE CYLINDER HEAD COVERS 5 25 CYLINDER HEADS 5 26 REMOVING THE CYLINDER HEADS 5 27 CHECKING THE CYLINDER HEADS 5 27 INSTALLING THE CYLINDER HEADS 5 27 VALVES AND VALVE SPRINGS 5 29 REMOVING THE VALVES 5 30 CHECKING THE VALVES AND VALVE GUIDES 5 30 CHECKING THE VALVE SEATS 5 32 CHECKING THE VALVE SPRINGS 5 33 INSTALLING THE VALVES 5 34 CYLINDERS AND PISTONS 5 36 REMOVING THE PISTONS 5 37 CHECKING T...

Page 210: ...G THE STOPPER LEVER 5 60 INSTALLING THE SHIFT SHAFT 5 60 ELECTRIC STARTER 5 61 CHECKING THE STARTER MOTOR 5 63 ASSEMBLING THE STARTER MOTOR 5 64 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 69 CHECKING THE CRANKCASE 5 69 CHECKING THE BEARINGS AND OIL SEAL 5 69 CHECKING THE OIL DELIVERY PIPES 5 69 CHECKING THE TIMING CHAINS 5 69 CHECKING THE OIL PUMP DRIVEN SPROCKET 5 69 INSTALLING THE BEARING RETA...

Page 211: ...SION 5 80 CHECKING THE SHIFT FORKS 5 83 CHECKING THE SHIFT DRUM ASSEMBLY 5 83 CHECKING THE TRANSMISSION 5 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 84 ...

Page 212: ... the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 0 kgf cm 14 5 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specifi...

Page 213: ...ENGINE INSPECTION 5 2 10 Install Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 3 ...

Page 214: ...aust pipe protector 3 1 14 Muffler protector 1 1 15 Muffler protector 2 1 16 Muffler cap 1 1 18 19 13 2 16 3 14 15 17 5 7 8 9 6 6 10 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT 5 LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T...

Page 215: ...0 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT 5 LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 7 Nm 0 7...

Page 216: ...xhaust pipe protector 2 bracket band so that its section to crimp is positioned at the location a shown in the illustration TIP Be sure to place the exhaust pipe protector 2 bracket band over the exhaust pipe protector 2 bracket d Crimp the exhaust pipe protector 2 bracket band using the boots band installation tool 4 3 Tighten Exhaust pipe protector 2 bolts 4 Install Exhaust pipe assembly T R Exh...

Page 217: ...own 2 Install Clamp 1 to the muffler assembly TIP Fit the projection a on the clamp into the slot b shown in the illustration Temporarily tighten the clamp bolt 2 3 Install Muffler assembly Muffler bracket 4 Tighten Clamp bolt Installed depth of gasket c 3 5 mm 0 14 in T R Muffler bolt 35 Nm 3 5 m kgf 25 ft lbf Muffler bracket bolt 53 Nm 5 3 m kgf 38 ft lbf New 1 c b a New 1 2 a b T R Clamp bolt 1...

Page 218: ... 8 Rear cylinder left cover bracket 1 9 Rear cylinder right cover bracket 1 10 Ground lead 1 Disconnect 11 Drive pulley housing 1 12 Neutral switch sub wire harness 1 13 Damper 1 14 Dowel pin 2 15 Sidestand switch coupler 1 Disconnect LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 20 Nm 2 0 m ...

Page 219: ...move Q ty Remarks LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 5 1 6 17 19 18 14 15 16 11 5 13 12 10 7 8 3 9 4...

Page 220: ...026 The shift rod locknut shift pedal side has left hand threads b Turn the shift rod 2 in direction a or b to obtain the correct shift rod length TIP Make sure that the engaged thread length on both ends of the shift rod is 4 ridges or more c Tighten the locknuts to specification d Make sure the installed shift rod length is within specification T R Shift arm bolt 16 Nm 1 6 m kgf 12 ft lbf Instal...

Page 221: ...manifold assem bly Refer to THROTTLE BODIES on page 6 7 1 Starter motor lead 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Oil level switch coupler 1 Disconnect 5 Rectifier regulator coupler 1 Disconnect 6 Clutch cable 1 Disconnect 7 Crankcase breather hose 1 8 Horn connector 2 Disconnect 9 Horn 1 For installation reverse the removal proce dure 30 N...

Page 222: ...INE REMOVAL 5 11 EAS1TP1070 INSTALLING THE HORN 1 Install Horn 1 TIP Make sure that the horn bracket 2 contacts the portion a of the stay on the frame T R Horn bracket bolt 30 Nm 3 0 m kgf 22 ft lbf 1 2 a ...

Page 223: ...de 2 7 Engine bracket front lower side 1 8 Engine mounting bolt rear lower side 1 9 Engine bracket bolt rear lower side 2 10 Engine bracket rear lower side 1 11 Engine bracket nut front upper side 2 12 Engine mounting bolt front upper side 1 13 Engine bracket bolt front upper side 2 14 Engine bracket front upper side 1 15 Lock washer 1 LT LT LT LS 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 f...

Page 224: ...For installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks LT LT LT LS 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 88 Nm 8 8 m kgf 64 ft Ibf T R 88 Nm 8 8 m kgf 64 ft Ibf T R 88 Nm 8 8 m kgf 64 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 1 2 3 15 7 6 6 5 13 12 8 14 11 16 4 17 17 18 10 9 9 19 ...

Page 225: ...15 Engine mounting nut rear upper side 16 Engine mounting nut front upper side 17 Engine mounting nut rear lower side 18 Engine mounting nut front lower side 19 TIP Lubricate the engine mounting bolt front lower side threads with lithium soap based grease Apply locking agent LOCTITE to the threads of the engine bracket bolts front lower side engine bracket bolts rear lower side and engine bracket ...

Page 226: ...ut rear lower side 18 Engine mounting nut front lower side 19 T R Engine mounting nut rear upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting 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 front lower side 88 Nm 8 8 m kgf 64 ft lbf 17 16 18 19 ...

Page 227: ... Intake manifold assembly Refer to THROTTLE BODIES on page 6 7 1 Tappet cover 4 2 O ring 4 3 Fuel filter bracket 1 4 Front cylinder side cover 1 5 Front cylinder side cover gasket 1 6 Rear cylinder side cover 1 7 Rear cylinder side cover gasket 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R FWD FWD LT L...

Page 228: ...hain 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 M E M FWD FWD 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 27 Nm 2...

Page 229: ... T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R New New 5 6 7 3 3 3 3 2 2 8 9 12 11 14 13 New 5 4 4 1 2 2 3 14 13 11 1 12 10 3 6 7 3 8 3 E E E E E 24 Nm 2 4 m kgf 17 ft ...

Page 230: ... I mark c on the camshaft sprocket with the arrow mark d on the front cylinder head 2 Remove Front cylinder timing chain tensioner 1 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 4 Remove Camshaft retainer Front cyli...

Page 231: ...the camshaft sprocket with the 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 Remove the parts using the same procedure as for the front cylinder camshaft and rocket arm EAS23840 CHECKING THE CAMSHAF...

Page 232: ...tion excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter 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 Exhaust A 42 138...

Page 233: ...ner 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 identified by the punch mark...

Page 234: ... mark c on the camshaft sprocket with the arrow mark d on the front cylinder 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 ro tor holding tool 2 tighten the camshaft sprock et...

Page 235: ... 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 wire fro...

Page 236: ...USTING THE VALVE CLEAR ANCE on page 3 4 EAS1TP1053 INSTALLING THE CYLINDER HEAD COVERS 1 Install Rear cylinder side cover Fuel filter bracket Tappet covers 2 Install Front cylinder side cover Tappet covers T R Rear cylinder timing chain ten sioner bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R Timing chain tensioner cap bolt 24 Nm 2 4 m kgf 17 ft lbf New New T R Rear cylinder side cover bolt 10 Nm 1 0 m kgf ...

Page 237: ...l pin 4 8 Cylinder head gasket 2 9 Timing chain guide exhaust side 1 10 Timing chain guide intake side 1 For installation reverse the removal proce dure 1st 15 Nm 1 5 m kgf 11 ft Ibf Final 65 Nm 6 5 m kgf 47 ft Ibf 2nd 25 Nm 2 5 m kgf 18 ft Ibf T R 1st 15 Nm 1 5 m kgf 11 ft Ibf Final 65 Nm 6 5 m kgf 47 ft Ibf 2nd 25 Nm 2 5 m kgf 18 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft I...

Page 238: ...damag 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 cylinder 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 cylinder head as follows d Place 400 600 grit wet sandpaper on a sur face ...

Page 239: ... cylinder head nuts in the proper tightening sequence as shown and torque them in three stages T R Cylinder head nut 1st 15 Nm 1 5 m kgf 11 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf Final 65 Nm 6 5 m kgf 47 ft lbf Cylinder head bolt 13 Nm 1 3 m kgf 9 4 ft lbf A Front cylinder head B Rear cylinder head ...

Page 240: ... ty Remarks The following procedure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 26 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 M M New New New New ...

Page 241: ... cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove 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 foll...

Page 242: ...tem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 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 0020 in Limit 0 100 mm 0 0039 in Valve guide position 12 7 13 1 mm 0 500 0 515 i...

Page 243: ...ts 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 cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where th...

Page 244: ...pping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the val...

Page 245: ... 3 Lubricate Valve stem end with the recommended lubricant 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 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed compression spring force exhaust 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed length intake 35 00 mm 1 38 in ...

Page 246: ...stall the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve a Larger pitch b Smaller pitch New Valve spring compressor 90890 04019 YM 04019 Va...

Page 247: ...rts to remove Q ty Remarks Cylinder heads Refer to CYLINDER HEADS on page 5 26 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 248: ...gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders 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 th...

Page 249: ...cation Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring in the cylinder with the pis ton crown 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 i...

Page 250: ...ification Replace the piston 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 60 mm 0 0236 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 installed 0 20 0 70 mm 0 0079 0 0276 in Piston p...

Page 251: ...iston fac es 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 lubrica...

Page 252: ...S AND PISTONS 5 41 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 253: ...e 5 3 1 Rectifier regulator coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Damper cover 1 4 Generator cover damper 1 5 Crankshaft end accessing screw 1 6 Timing mark accessing screw 1 7 Oil level gauge 1 8 Generator cover 1 9 Generator cover gasket 1 10 Dowel pin 2 11 Crankshaft position sensor lead holder 1 12 Crankshaft position sensor 1 LT LT LT 11 1 12 13 10 9 7 4 3 5...

Page 254: ... For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks LT LT LT 11 1 12 13 10 9 7 4 3 5 6 10 8 2 12 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 255: ... 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 E LT 2 4 3 8 5 7 6 1 24 Nm 2 4 m kgf 17 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R ...

Page 256: ...er clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 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 clutch gear ...

Page 257: ...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 key way of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 TIP While h...

Page 258: ...UTCH 5 47 EAS1TP1054 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 T R Generator cover bolt 12 Nm 1 2 m kgf 8 7 ft lbf ...

Page 259: ...er Refer to GENERATOR AND STARTER CLUTCH on page 5 42 Rear brake master cylinder Right footrest as sembly Rear brake light switch Refer to REAR BRAKE on page 4 35 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Clutch plastic cover 1 1 5 Clutch plastic cover 2 1 6 Clutch cover 1 7 Clutch cable holder 1 LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 f...

Page 260: ...ive gear 1 15 Woodruff key 1 For installation reverse the removal proce dure Removing the primary drive gear Order Job Parts to remove Q ty Remarks LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 100 Nm 10 m kgf 72 ft lbf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 5 6 4 9 7 8 7 3 2 1 10 10 10 15 14 13 12 11 ...

Page 261: ...er 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 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 262: ...n 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 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New 6 9 8 8 8 8 8 8 8 9 9 9 9 9 9 7 5 6 14 13 12 7 8 19 18 17 16 15 1...

Page 263: ...er 2 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New 6 9 8 8 8 8 8 8 8 9 9 9 9 9 9 7 5 6 14 13 12 7 8 19 18 17 16 15 10 11 1 2 3 4 ...

Page 264: ...h boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 3 Remove Clutch boss nut 1 Conical spring washer 2 Clutch boss 3 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specific...

Page 265: ...ge Replace 3 Measure Clutch spring free height Out of specification Replace the clutch spring plate EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation Friction plate 1 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 11...

Page 266: ...eplace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 2 Check Pull rod bearing Damage wear Replace EAS1TP1055 CHE...

Page 267: ...es with engine oil Install the conical spring washer with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss nut 3 at cutout b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates 2 Clutch plates Friction plates 1 TIP First install a friction pla...

Page 268: ...g 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 mark c on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 10 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 10 T R Clutch spring...

Page 269: ...sher with the groove b in the spacer While holding the generator rotor 4 with the sheave holder 5 tighten the primary drive gear nut Do not allow the sheave holder to touch the projection on the generator rotor Lubricate the primary drive gear nut threads with engine oil 2 Bend lock washer tab along a flat side of the nut T R Primary drive gear nut 100 Nm 10 m kgf 72 ft lbf Sheave holder 90890 017...

Page 270: ... 70 Shift arm Refer to ENGINE REMOVAL on page 5 3 Clutch cover Clutch housing Refer to CLUTCH on page 5 48 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 LS E E 22 Nm 2 2 m kgf 16 ft Ibf T R 8 9 3 4 5 6 2 1 7 ...

Page 271: ...HAFT 1 Install Bearing 1 Oil seals 2 to the crankcase 2 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 seg ment assembly Hook the end of the shift shaft spring onto the shift shaft spring st...

Page 272: ...ng 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 2 ...

Page 273: ... 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 New New 5 Nm 0 5 m kgf 3 6 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 274: ...embly resistances with the pocket tester b If any resistance is out of specification re place 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 6 Check Gear teeth Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Mo...

Page 275: ...r 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 mo tor front and rear covers ...

Page 276: ...n page 5 59 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 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kg...

Page 277: ... to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R E ...

Page 278: ...late 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 15 Nm 1 5 m kgf 11 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 19 ...

Page 279: ...arts to remove Q ty Remarks Oil pump assembly Refer to OIL PUMP on page 5 72 Crankshaft Refer to CRANKSHAFT on page 5 75 Transmission Refer to TRANSMISSION on page 5 80 1 Bearing retainer 2 2 Oil seal 1 3 Bearing 5 For installation reverse the removal proce dure ...

Page 280: ...ages Obstruction Blow out with compressed air EAS1TP1056 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 EAS1TP1057 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 D...

Page 281: ...nstall Crankcase bolts M10 Crankcase bolts M6 Oil baffle plate 1 bolts TIP Apply locking agent LOCTITE to the threads of the right crankcase bolts and oil baf fle plate 1 bolts Tighten the crankcase bolts in the proper tight ening sequence as shown in the illustration M10 110 mm bolts M6 120 mm bolts a Oil baffle plate 1 bolts b M6 80 mm bolts T R Bearing retainer bolt 12 Nm 1 2 m kgf 8 7 ft lbf L...

Page 282: ...CRANKCASE 5 71 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair ...

Page 283: ...lief 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 E 8 Nm 0 8 m kgf 5 8 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R ...

Page 284: ...ring 3 Spring retainer 4 Damage wear Replace the relief valve as sembly EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the recommended lubricant 2 Install Pin 1 Oil pump inner rotor 2 Oil pump outer rotor 3 Dowel pin Oil pump housing 4 Inner rotor to outer rotor tip c...

Page 285: ...ump operation Refer to CHECKING THE OIL PUMP on page 5 73 EAS1TP1060 INSTALLING THE OIL PUMP ASSEMBLY 1 Install Oil pump assembly NOTICE ECA1TP1021 After tightening the bolts make sure the oil pump assembly turns smoothly T R Oil pump housing screw 8 Nm 0 8 m kgf 5 8 ft lbf T R Oil pump assembly bolt 24 Nm 2 4 m kgf 17 ft lbf 1 2 3 4 a a ...

Page 286: ...nkshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 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 287: ...the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pin and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end...

Page 288: ...ance is out of specification select re placement 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 crank shaft illustration For example if the connecting rod P1 number is 5 then the bearing size for P1 is 5 brown 5 Measure Crankshaft journal diameter a Out of...

Page 289: ...mended 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 connect ing rod faces towards the left side of the crank shaft Make sure the c...

Page 290: ...en and then retighten it Replace the bolt with a new one and perform the procedure again NOTICE ECA1TP1022 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 ASSEMBLY 1 Install Crankshaft assembly NOTICE ECA1TP1023 To avoid scratching the crankshaft and to ease the installation procedure lubri...

Page 291: ...Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 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 292: ...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 293: ...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 294: ...h 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 as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a cent...

Page 295: ...ds 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 projection 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 w...

Page 296: ...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 297: ...MP 6 5 INSTALLING THE FUEL SENDER 6 6 THROTTLE BODIES 6 7 CHECKING THE INJECTORS 6 10 INSTALLING THE INJECTORS 6 10 CHECKING THE THROTTLE BODIES 6 10 CHECKING THE INTAKE MANIFOLD JOINTS 6 10 CHECKING THE PRESSURE REGULATOR OPERATION 6 10 ADJUSTING THE THROTTLE POSITION SENSOR 6 11 REMOVING THE INTAKE MANIFOLD ASSEMBLY 6 12 INSTALLING THE INTAKE MANIFOLD ASSEMBLY 6 12 ...

Page 298: ...1 Disconnect 6 Fuel hose fuel pump to fuel hose 1 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel sender 1 10 Fuel pump cover 1 11 Fuel pump 1 12 Fuel tank bracket 1 13 Fuel tank bracket damper 1 14 Fuel tank stopper 2 For installation reverse the removal proce dure New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf ...

Page 299: ...For California 6 Fuel tank breather overflow hose fuel tank to fuel hose joint 1 7 Fuel hose joint 1 8 Fuel tank breather overflow hose fuel hose joint to rollover valve 1 9 Rollover valve 1 10 Fuel tank breather overflow hose holder 1 Except for California 11 Fuel tank breather overflow hose rollover valve to canister 1 For California 12 Fuel tank breather overflow hose 1 Except for California 13...

Page 300: ...ia For installation reverse the removal proce dure Removing the rollover valve and canister Order Job Parts to remove Q ty Remarks 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 7 8 1 2 3 5 4 10 11 14 9 12 13 ...

Page 301: ...uel hose to fuel fil ter slide the fuel hose connector lock 3 in the direction of the arrow shown using a slotted head screwdriver and then disconnect the hose Disconnect the fuel hose from the fuel pump and fuel filter manually without using any tools Before disconnecting the hose place a few rags in the area under where it will be removed 2 Remove Fuel pump cover TIP When removing the fuel pump ...

Page 302: ...lip a shall face toward the fuel tank Tighten the fuel pump bolts in the proper tight ening sequence as shown 2 Install Fuel hoses NOTICE ECA1TP1017 When installing a fuel hose make sure that it is securely connected and that the fuel hose connector cover or fuel hose connector lock is in the correct position otherwise the fuel hose will not be properly installed TIP Connect the fuel hoses until a...

Page 303: ...1 Install Fuel sender O ring TIP Position the fuel sender coupler 1 between the guides a on the fuel tank bracket 2 A Connection to fuel pump and fuel filter B Connection between fuel hoses T R Fuel sender bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1 A 2 B New 2 1 a ...

Page 304: ...er purge hose 1 Disconnect For California 3 Intake air pressure sensor hose 1 Disconnect 4 Throttle cable 2 Disconnect 5 Throttle body 1 NOTICE ECA1TP1018 The throttle body should not disassem bled 6 Gasket 1 7 ISC idle speed control unit coupler 1 Disconnect 8 Throttle position sensor 1 For installation reverse the removal proce dure New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf...

Page 305: ...rnia Refer to FUEL TANK on page 6 1 1 Engine temperature sensor coupler 1 Disconnect 2 Fuel injector coupler 2 Disconnect 3 Fuel filter 1 4 Fuel filter cover 1 5 Fuel return hose 1 6 Intake manifold joint clamp screw 2 Loosen 7 Intake manifold assembly 1 8 Rear cylinder intake manifold joint 1 9 Front cylinder intake manifold joint 1 For installation reverse the removal proce dure E E E 10 Nm 1 0 ...

Page 306: ...move Q ty Remarks 1 Pressure regulator 1 2 Inlet pipe assembly 1 3 Injector 2 4 Intake manifold 1 For assembly reverse the disassembly pro cedure LT New New New New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 4 1 2 3 3 ...

Page 307: ... the bolts from being tightened to the specified torque 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 7 27 EAS1TP1041 INSTALLING THE INJECTORS 1 Install the injectors to the inlet pipe assembly 2 Install a seal onto the end of each injector 3 Install the inlet pipe assembly to the intake manifold EAS26990 CHECKING THE THROTTLE BODIES 1 Check Throttle bodies Crac...

Page 308: ...Measure the throttle position sensor output voltage e Adjust the throttle position sensor angle so that the output voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 2 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 Pressure gauge 90890 03153 YU 03153 Fuel pressure adapter 90890 031...

Page 309: ...r intake manifold joint 2 to the intake manifold assembly TIP Be sure to fit the projection b on the intake manifold assembly between the projections c on the rear cylinder intake manifold joint c Install the intake manifold assembly TIP Lubricate the rear cylinder intake manifold joint and rear cylinder head mating surfaces with engine oil Position the intake manifold assembly 3 as shown in the i...

Page 310: ...THROTTLE BODIES 6 13 ...

Page 311: ...OOTING 7 10 CHARGING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING 7 15 LIGHTING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 19 SIGNALING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 23 FUEL INJECTION SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 ECU SELF DIAGNOSTIC FUNCTION 7 29 TROUBLESHOOTING METHOD 7 30 YAMAHA DIAGNOSTIC TOOL 7 31 TROUBLESHOOTING DETAILS 7 32 FUEL PUMP SYSTEM 7 67 CIRCUIT D...

Page 312: ... CRANKSHAFT POSITION SENSOR 7 86 CHECKING THE LEAN ANGLE SENSOR 7 87 CHECKING THE STARTER MOTOR OPERATION 7 87 CHECKING THE STATOR COIL 7 88 CHECKING THE RECTIFIER REGULATOR 7 88 CHECKING THE OIL LEVEL SWITCH 7 89 CHECKING THE FUEL SENDER 7 89 CHECKING THE FUEL LEVEL WARNING LIGHT 7 89 CHECKING THE OIL LEVEL WARNING LIGHT 7 90 CHECKING THE SPEED SENSOR 7 90 CHECKING THE ENGINE TEMPERATURE SENSOR 7...

Page 313: ......

Page 314: ...L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B Db L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy...

Page 315: ...coupler 17 Relay unit 20 Sidestand switch 21 Neutral switch 26 Crankshaft position sensor 27 Lean angle sensor 32 ECU engine control unit 33 Front cylinder ignition coil 34 Spark plug 35 Rear cylinder ignition coil 67 Right handlebar switch 69 Engine stop switch A Wire harness B Negative battery sub wire harness C Neutral switch sub wire harness ...

Page 316: ...eventing 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 down the sidestand switch is open 1 4 5 10 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch ...

Page 317: ...ARGING THE BATTERY on page 7 80 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 85 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7 85 Replace the spark...

Page 318: ...E SWITCHES on page 7 75 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 84 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 87 Replace the lean angle sensor 14 Check the entire ignitio...

Page 319: ...IGNITION SYSTEM 7 6 ...

Page 320: ... L B L B R B B B B B B B P W Y G B L B Y P L B L B R L L G B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P ...

Page 321: ... Starter motor 13 Ignition fuse 16 Joint coupler 17 Relay unit 18 Starting circuit cut off relay 20 Sidestand switch 21 Neutral switch 56 Clutch switch 67 Right handlebar switch 69 Engine stop switch 70 Start switch A Wire harness B Negative battery sub wire harness C Neutral switch sub wire harness ...

Page 322: ...the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch a WHEN THE TRANSMISSION IS IN NEUTRAL b WHEN THE SIDESTAND ...

Page 323: ...echarge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 87 The starter motor is OK Perform the elec tric starting system troubleshooting start ing with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 63 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer t...

Page 324: ...G THE SWITCHES on page 7 75 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the right handlebar switch 14 Check the entire starting system wiri...

Page 325: ...ELECTRIC STARTING SYSTEM 7 12 ...

Page 326: ...L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy W ...

Page 327: ...CHARGING SYSTEM 7 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 5 Battery A Wire harness B Negative battery sub wire harness ...

Page 328: ...o CHECKING AND CHARGING THE BATTERY on page 7 80 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 88 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 88 Replace the rectifier regulator 5 Check the entire charging system wiring Re...

Page 329: ...CHARGING SYSTEM 7 16 ...

Page 330: ...L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy W ...

Page 331: ...ter 46 Meter light 47 High beam indicator light 51 Headlight relay 52 Left handlebar switch 53 Dimmer switch 57 Auxiliary light OPTION 59 Headlight 60 Front left turn signal position light 61 Front right turn signal position light 64 License plate light 65 Tail brake light assembly 66 Tail brake light A Wire harness B Negative battery sub wire harness E Rear turn signal light and license plate lig...

Page 332: ...and bulb socket s 2 Check the fuses Main headlight fuel injection sys tem signaling system ignition and tail brake light Refer to CHECKING THE FUS ES on page 7 79 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 80 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the ma...

Page 333: ...ING SYSTEM 7 20 NG OK 7 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 17 Properly connect or replace the wire har ness Replace the ECU meter assembly or tail brake light assembly ...

Page 334: ... L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy W...

Page 335: ...rning light 48 Turn signal indicator light 49 Fuel sender 50 Turn signal relay 52 Left handlebar switch 54 Turn signal switch 55 Horn switch 58 Horn 60 Front left turn signal position light 61 Front right turn signal position light 62 Rear left turn signal light 63 Rear right turn signal light 65 Tail brake light assembly 66 Tail brake light 68 Front brake light switch 73 Rear brake light switch A...

Page 336: ...ystem ignition fuel injection system and backup Refer to CHECKING THE FUS ES on page 7 79 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 80 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIA...

Page 337: ...ight switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or replace the wire har ness Replace the tail brake light assembly 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 78 Replace the turn signal light bulb s ...

Page 338: ...the neutral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 84 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 7 89 Replace the oil level switch 2 Check the e...

Page 339: ...n page 7 21 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 7 90 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or replace the wire har ness Replace the ECU or meter assembly ...

Page 340: ...B L B L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B...

Page 341: ...tion sensor 27 Lean angle sensor 28 Throttle position sensor 29 Intake air pressure sensor 30 ISC idle speed control unit 31 Yamaha diagnostic tool coupler 32 ECU engine control unit 33 Front cylinder ignition coil 34 Spark plug 35 Rear cylinder ignition coil 36 Front cylinder injector 37 Rear cylinder injector 38 Fuel pump 40 Meter assembly 42 Multi function meter 43 Engine trouble warning light ...

Page 342: ...elow is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If t...

Page 343: ...ode number is dis played 5 Erase the malfunction history in the diagnos tic mode code No 62 Refer to SELF DI AGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 8 5 TIP Turning the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diag...

Page 344: ... basic vehicle functions such as adjusting the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap and then connect the Yamaha diagnostic tool to the coupler 1 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation Yamaha diagnostic tool US 90890 03216 Fault dia...

Page 345: ...Confirmation of service completion 1 Connection of crankshaft po sition sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Crank the engine Fault code number is not dis played Service is finished Fault code numb...

Page 346: ...ntake air pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection ...

Page 347: ...ayed Go to item 6 6 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft abov...

Page 348: ...se condition Clogged or detached hose Repair or replace the sen sor hose Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditi...

Page 349: ...e locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re plac...

Page 350: ...nd with the transmission in gear Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of sidestand switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn...

Page 351: ...ue yellow blue yellow Between main switch coupler and joint connector blue black blue black Between joint connector and ECU coupler blue black blue black Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Defective sidestand switch Execute the diagnostic mode Code No 20 Shift th...

Page 352: ...Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Wire harness continuity Open or short circuit Re place the wire harness Between intake a...

Page 353: ...Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Installed condition of O2 sen sor Improperly installed sensor Reinstall or replace the sensor Start the engine warm it up and then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connect...

Page 354: ...3 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Check fuel pressure Refer to CHECKING THE PRESSURE REGULATOR OPERATION on page 6 10 Start the engine warm it up and then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Defective O2 sensor C...

Page 355: ... engine temperature sensor coupler and ECU coupler brown brown Between engine temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of engine temperature sensor Check for loose...

Page 356: ...alled direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 An indicated value is out of the specified range Re place the lean angle sensor Turn the main switch to ON then to OFF and then...

Page 357: ...is played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between front cylinder igni tion coil coupler and ECU coupler orange orange Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of front cylinder ignition coil Check for l...

Page 358: ... coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit...

Page 359: ... then fully opens the valve ISC operating sound is heard Go to item 2 ISC operating sound is not heard Go to item 2 in sec tion B for the defective ISC idle speed control unit 2 Incorrect speed sensor sig nal Check the speed sensor Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indi cated value increases Value does not increase Go to fault code No 42 Start ...

Page 360: ... heard Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 54 Actuation Fully closes the ISC valve and then opens the valve This opera tion is performed 3 times and takes approximately 4 seconds each time The engine trouble warning light comes on during the opera tion Procedure The ISC unit vibrates when the ISC valve operates Item Probable cause of mal function and chec...

Page 361: ...ISC idle speed control coupler and ECU coupler red green red green pink blue pink blue white green white green brown brown Between ISC idle speed control coupler and relay unit coupler red black red black red black red black Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item 8 and delete the fault code ISC operating sound is not heard Go to item 5 5 Installed condition ...

Page 362: ...cond intervals Illuminates the engine trouble warning light Procedure Check that front cylinder injector is actuated five times by listening for the operating sound 37 Actuation Actuates rear cylinder injector five times at one second intervals Illuminates the engine trouble warning light Procedure Check that rear cylinder injector is actuated five times by listening for the operating sound Item P...

Page 363: ...r bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code Nos 36 37 No operating sound Go to item 5 Operating sound Go to item 7 5 Wire harness continuity Open or short circuit Re place the wire harness Between injector coupler and ECU coupler Front cylinder injector gray gray Rear cylinder...

Page 364: ... Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between lean angle sensor coupler and ECU coupler yellow green yellow green Between lean angle sensor coup...

Page 365: ...d value increases Value does not increase Go to item 2 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Incorrect indication Go to item 2 in section B for the neutral switch When the transmission is in gear with the clutch lever squeezed and the sidestand retracted ON Incorrect indication Go to item 2...

Page 366: ...oupler and ECU coupler white yellow white yellow Between speed sensor cou pler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indi cated value increases Value increases Go to item 6 and delete the fault code Value does not increase Go to i...

Page 367: ...Value does not increase Go to item 2 in section A for the speed sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Incorrect indication Go to item 2 When the transmission is in gear with the clutch lever squeezed and the sidestand is retracted ON Incorrect indication Go to item 2 in section C for...

Page 368: ...agnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item 9 Incorrect indication Go to item 5 5 Defective relay unit Check the relay unit Refer to CHECKING THE RELAY UNIT DIODE on page 7 84 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in...

Page 369: ...heck that the fault code number is not displayed Fault code No 42 Item A Speed sensor no normal signals are received from the speed sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21 Indicated Neutral ON when the transmission is in neutral OFF when the transmis...

Page 370: ... No 21 When the transmission is in gear with the clutch lever is released and the sidestand retracted OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 3 3 Connection of clutch switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improper...

Page 371: ...lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 6 6 Wire harness continuity Between clutch switch cou pler and relay unit coupler blue yellow black yellow When the clutch lever is re leased open circuit When the clutch lever is squeezed short circuit Open or short circuit Re place the clutch switch Execute the diagnostic mode Code No 21 When the transmission is...

Page 372: ...the operating sound Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of relay unit cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Start the engine and l...

Page 373: ...agnostic mode Code No 09 Fuel system voltage is be low 3 V Replace the relay unit Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 44 Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system...

Page 374: ...s dis played Repeat the mainte nance job Fault code No 50 Item Faulty ECU engine control unit memory When this malfunc tion is detected in the ECU the fault code number might not appear Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Malfunction ...

Page 375: ...yed Service is finished Fault code number is dis played Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 2 Item ECU engine control unit internal malfunction output signal error no signals are received...

Page 376: ...ror data from the ECU cannot be received correctly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of meter assem bly coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals an...

Page 377: ...ition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of ECU coupler Check the locking condition of the couple...

Page 378: ...n switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 4 Item ECU engine control unit internal malfunction input signal er ror non registered data has been received from the meter ...

Page 379: ...FUEL INJECTION SYSTEM 7 66 ...

Page 380: ... L B L B R B B B B B B B P W Y G B L B Y P L B L B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy W...

Page 381: ...se 5 Battery 7 Fuel injection system fuse 13 Ignition fuse 16 Joint coupler 17 Relay unit 19 Fuel pump relay 32 ECU engine control unit 38 Fuel pump 67 Right handlebar switch 69 Engine stop switch A Wire harness B Negative battery sub wire harness ...

Page 382: ...Y on page 7 80 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 75 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 7 83 Replace the relay unit 6 Check the fuel ...

Page 383: ...FUEL PUMP SYSTEM 7 70 ...

Page 384: ...ELECTRICAL COMPONENTS 7 71 EAS27970 ELECTRICAL COMPONENTS 3 1 2 5 4 7 8 9 10 11 12 13 6 ...

Page 385: ...ntake air pressure sensor 3 Front cylinder ignition coil 4 Rear cylinder ignition coil 5 Turn signal relay 6 ECU engine control unit 7 Speed sensor 8 Neutral switch 9 O2 sensor 10 Oil level switch 11 Crankshaft position sensor 12 Engine temperature sensor 13 Horn ...

Page 386: ...ELECTRICAL COMPONENTS 7 73 1 2 5 7 9 8 6 20 19 18 17 4 3 11 12 13 14 15 16 10 ...

Page 387: ... angle sensor 6 Headlight relay 7 Starter relay 8 Fuel injection system fuse 9 Main fuse 10 Fuse box 11 Ignition fuse 12 Signaling system fuse 13 Tail brake light fuse 14 Backup fuse 15 Headlight fuse 16 Spare fuse 17 Rectifier regulator 18 Sidestand switch 19 Rear brake light switch 20 Fuel sender ...

Page 388: ...ELECTRICAL COMPONENTS 7 75 EAS27980 CHECKING THE SWITCHES 1 Br R L L Y 6 5 7 4 3 2 L L Y R Br P P Y G B Y B R Br B W L W R W B B W Br Y G Y R B Y Br W Dg P Br L O O B Ch L Y L ...

Page 389: ... switch 2 Front brake light switch 3 Reset switch 4 Select switch 5 Engine stop switch 6 Start switch 7 Rear brake light switch 8 Neutral switch 9 Sidestand switch 10 Dimmer switch 11 Turn signal switch 12 Horn switch 13 Clutch switch ...

Page 390: ...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 given sw...

Page 391: ...the bulbs The following 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 NOTICE ECA1TP1001 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the gl...

Page 392: ...ester 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 circuit WARNING EWA13310 Never ...

Page 393: ...different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the b...

Page 394: ...l contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illus...

Page 395: ...ge 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 bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A...

Page 396: ...ircuit 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 between 3 and 4 R B R W L 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Re...

Page 397: ...signal relay output voltage EAS1TP1063 CHECKING THE RELAY UNIT DIODE Relay unit diode 1 Check Relay unit diode Out of specification Replace TIP The pocket tester or the analog pocket tester readings are shown in the following table 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 voltag...

Page 398: ...ire 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 Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester p...

Page 399: ... resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1 k to the ig nition coil as shown c Measure the secondary coil resistance EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness Resistance 7 5 12 5 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 ...

Page 400: ...Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 7 4 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This ch...

Page 401: ...ead of the front cylinder b Connect the pocket tester DC 20 V to the battery terminals as shown c Start the engine and operate it run at approx imately 5000 r min d Measure the charging voltage Stator coil resistance 0 128 0 192 Ω Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe black 1 Negative tester probe black 2 Positive tester probe black ...

Page 402: ...0 CHECKING THE FUEL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Oil level switch Maximum level position resis tance 484 536 Ω Minimum level...

Page 403: ...P 1 to the speed sensor and wire har ness as shown b Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown c Set the main switch to ON d Elevate the rear wheel and slowly rotate it e 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 ...

Page 404: ... sensor ad just its angle properly Refer to THROTTLE BODIES on page 6 7 EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sensor 3P 1 to the intake air pressure sensor and wire harness as shown b Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown En...

Page 405: ... Slowly heat the water and then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance EAS1TP1012 CHECKING THE FUEL INJECTORS The following procedure applies to all off the fuel injectors 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from wire harness b Connect the pocket tester ...

Page 406: ...ELECTRICAL COMPONENTS 7 93 c Measure the fuel injector resistance ...

Page 407: ...R MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 2 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8 5 ...

Page 408: ...ty 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 damaged insulator Faulty spark p...

Page 409: ... shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 ...

Page 410: ...nt 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 ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly ten...

Page 411: ...correct 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 signal remains lit Faulty turn signal relay Burnt out turn signal bulb Turn signal flashes quickly Incorrect turn signal bulb Faulty turn signal r...

Page 412: ...er ignition coil open or short circuit detected in the prima ry lead of the front cylinder ignition coil 7 43 34 Rear cylinder ignition coil open or short circuit detected in the primary lead of the rear cylinder ignition coil 7 45 37 Component other than ISC idle speed control unit is defective ISC operating sound is heard 7 46 Defective ISC idle speed control unit ISC operating sound is not hear...

Page 413: ... been received from the meter 7 64 Diagnostic code No Item Display Procedure 01 Throttle position sensor signal Fully closed position 14 20 Check with throttle valves fully closed Fully open position 92 102 Check with throttle valves fully open 02 Atmospheric pressure Displays the atmospheric pressure Compare the actually measured atmospheric pressure with the display value 03 Intake air pressure ...

Page 414: ...n gear Stand retracted ON Stand extended OFF 21 Neutral switch and clutch switch Operate the transmission clutch lever and side stand Transmission is in neu tral ON Transmission is in gear or the clutch lever re leased OFF Clutch lever is squeezed with the transmission in gear and when the side stand is retracted ON Clutch lever is squeezed with the transmission in gear and when the side stand is ...

Page 415: ...occurred since the histo ry was last erased For example if there have been three malfunc tions 03 is displayed To erase the history set the start engine stop switch from to 63 Malfunction code rein statement for fault code No 24 only No malfunction code 00 Malfunction code exists Fault code 24 To reinstate set the start engine stop switch from to 70 Control number 0 254 Diagnostic code No Item Dis...

Page 416: ...ening for the operating sound 50 Relay unit Actuates the relay unit five times at one second inter vals Illuminates the engine trouble warning light and Yamaha diagnostic tool warning light The engine trouble warn ing light and Yamaha diag nostic tool warning light are OFF when the relay is ON and the engine trou ble warning light and Yamaha diagnostic tool warning light are ON when the relay is O...

Page 417: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8 10 ...

Page 418: ...al switch 55 Horn switch 56 Clutch switch 57 Auxiliary light OPTION 58 Horn 59 Headlight 60 Front left turn signal position light 61 Front right turn signal position light 62 Rear left turn signal light 63 Rear right turn signal light 64 License plate light 65 Tail brake light assembly 66 Tail brake light 67 Right handlebar switch 68 Front brake light switch 69 Engine stop switch 70 Start switch 7...

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Page 421: ...B L B L B L B R B B B B B B B B R B R R R Br L L L Y R R Br R B R W L B R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B Br Br Br Br Br G Br Y B L B L B L B L B L B L B L B L B L R B R B R B B R Y Br Y B G L Br W Br G W Y Y R B Db L W Y B L Gy W R W Gy G B L B B B B L W B Br B L Br W B B L B Gy G Y B L L Y G B L B L Y B L B B L P W L W G R B R G Br R B P L B Gy W G Gy W Gy Db W R ...

Page 422: ...B B B B Gy B B B Gy Gy Gy B Gy B Gy B B B B SELECT RESET E E E D D D D C C L N R A B Db Db B B B B Gy 1 2 3 4 5 6 7 8 9 12 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 50 51 16 16 16 10 ...

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Yamaha STAR XVS95CE 1TP1 2014, Service Manual

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