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Yamaha Vmax VMX17C 2009, Service Manual

The Yamaha Vmax VMX17C 2009 is a powerhouse motorcycle offering an exhilarating riding experience. To ensure your bike stays in top-notch condition, a comprehensive Service manual is available for free download. Get all the vital information and maintenance guides you need from our website, manualshive.com.

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COOLING SYSTEM DIAGRAMS

2-44

1. Thermostat inlet pipe (rear cylinder side)
2. Thermostat inlet hose (rear cylinder side)
3. Thermostat housing
4. Radiator cap
5. Thermostat inlet hose 2 (front cylinder side)
6. Coolant reservoir hose
7. Thermostat inlet pipe 2 (front cylinder side)
8. Thermostat inlet hose 1 (front cylinder side)
9. Thermostat inlet pipe 1 (front cylinder side)
10. Water pump outlet pipe
11. Water pump inlet pipe
12. Oil cooler inlet hose
13. Oil cooler outlet hose
14. Impeller shaft
A. Align the paint mark on the thermostat inlet pipe 

(rear cylinder side) with the paint mark on the 
thermostat inlet hose (rear cylinder side).

B. Align the paint mark on the thermostat inlet hose 

(rear cylinder side) with the rib on the thermostat 
housing.

C. Align the paint mark on the thermostat inlet hose 2 

(front cylinder side) with the rib on the thermostat 
housing.

D. Align the tape on the ignition coil sub-wire harness 

2 with the paint mark on the thermostat inlet pipe 1 
(front cylinder side) and then fasten the ignition coil 
sub-wire harness 2 to the thermostat inlet pipe 1 
(front cylinder side) with the plastic holder.

E. Align the paint mark on the thermostat inlet pipe 2 

(front cylinder side) with the paint mark on the 
thermostat inlet hose 1 (front cylinder side).

F. Align the paint mark on the thermostat inlet pipe 1 

(front cylinder side) with the paint mark on the 
thermostat inlet hose 1 (front cylinder side).

G. Align the paint mark on the thermostat inlet pipe 2 

(front cylinder side) with the paint mark on the 
thermostat inlet hose 2 (front cylinder side).

H. Install the oil cooler outlet hose with its paint mark 

facing upward.

I.

Align the paint mark on the water pump outlet pipe 

with the paint mark on the oil cooler inlet hose.

Summary of Contents for Vmax VMX17C 2009

Page 1: ...2009 SERVICE MANUAL VMX17Y C LIT 11616 22 64 2S3 28197 10 ...

Page 2: ...y Yamaha Motor Corporation U S A First edition August 2008 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 22 64 ...

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

Page 5: ...ITION 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 G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ...DIAGNOSIS FUNCTION 1 17 ABS WARNING LIGHT AND OPERATION 1 20 YCC T YAMAHA CHIP CONTROLLED THROTTLE YCC I YAMAHA CHIP CONTROLLED INTAKE 1 22 INSTRUMENT FUNCTIONS 1 26 IMPORTANT INFORMATION 1 34 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 34 REPLACEMENT PARTS 1 34 GASKETS OIL SEALS AND O RINGS 1 34 LOCK WASHERS PLATES AND COTTER PINS 1 34 BEARINGS AND OIL SEALS 1 35 CIRCLIPS 1 35 CHECKING THE CONNECTI...

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: ... 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 using a microprocessor that regulates the fuel injection volume accord...

Page 12: ...mperature sensor cylinder identification sensor atmospheric pressure sensor lean angle sensor crankshaft position sensor intake air pres sure sensor intake air temperature sensor rear wheel 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: ...of the Yamaha ABS brakes is the same as conventional brakes on other vehicles with a brake lever for operating the front brake and a brake pedal for operating the rear brake When wheel lock is detected during emergency braking hydraulic control is performed by the hydraulic system on the front and rear brakes independently 1 5 3 4 A 6 7 9 10 11 8 12 13 3 4 A 2 1 ABS ECU fuse 2 ABS test coupler 3 H...

Page 14: ...slippage and is defined by the following formula 0 There is no slipping between the wheel and the road surface The chassis speed is equal to the wheel speed 100 The wheel speed is 0 but the chassis is moving i e wheel lock Brake force and vehicle stability When the brake pressure is increased wheel speed is reduced Slipping occurs between the tire and the road surface and brake force is generated ...

Page 15: ...heel speed reduction rate exceed the preset values the ABS ECU de termines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figure the ABS ECU reduces the brake fluid pressure in the brake caliper Once the ABS ECU determines that the tendency of the wheel to lock has diminished after the brake fluid pressure is reduced it incr...

Page 16: ...ays WARNING EWA2S31031 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even in vehicles equipped with ABS overturning of the vehicle cannot be prevented if it is braked suddenly The ABS functions to prevent the tendency of the wheel to lock by contr...

Page 17: ...lso includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly 1 comes on The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou bleshooting a Friction force between the tire and road surface b...

Page 18: ...the sensor housing for each wheel Sensor rotors 2 are installed on the inner side of the front and rear wheel hubs and rotate with the wheels 1 2 3 4 4 7 7 5 6 6 8 9 9 10 11 12 13 14 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master cylinder 4 Inlet solenoid valve 5 ABS motor 6 Hydraulic pump 7 Outlet solenoid valve 8 ABS ECU 9 Buffer chamber 10 Rear brake caliper 11 Rear...

Page 19: ...e ABS warning light 1 comes on to warn the rider if a malfunction in the ABS occurs When the main switch is turned to ON the ABS warning light comes on for 2 seconds then goes off so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating properly NOTICE ECA2S31063 If the rear wheel is raced with the vehicle on a suitable stand the ABS warning light may ...

Page 20: ... is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is closed The brake line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the inlet solenoid valve 1 closes and the outlet solenoid valve 2 opens ...

Page 21: ... 1 12 Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 2 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Raised piston ...

Page 22: ...de is stored in the memory of the ABS ECU for easy problem identification and troubleshooting 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 28 29 30 31 18 19 16 25 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS ECU fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Front brake light switch 10 Rear brake light switch 11 Tail brake light 12 Hydraulic unit assembl...

Page 23: ...at and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but these do not indicate a malfunction EAS2S31086 ABS OPERATION The ABS hydraulic circuit consists of two systems the front wheel and rear wheel The following de scribes the system for the front wheel only 2 1 3 4 5 6 7 8 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self ...

Page 24: ... At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master cylinder 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 H...

Page 25: ...outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 26: ...ing the brake fluid to be sent to the brake caliper EAS2S31087 ABS SELF DIAGNOSIS FUNCTION ABS warning light The ABS warning light 1 comes on when a malfunction is detected by the ABS self diagnosis It is located in the meter assembly 1 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve...

Page 27: ...efer to ELECTRIC STARTING SYSTEM on page 8 7 3 The ABS warning light comes on while riding If the ABS warning light comes on while riding a malfunction has been detected in the ABS The ABS hydraulic control will not be performed The ABS will have recourse to manual braking if this occurs 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f AB...

Page 28: ...ed on the multi function display when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS The ABS test coupler can be accessed by removing left side cover When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function display indicates all the fault codes recorded in the ABS ECU TIP The ABS w...

Page 29: ...ABS operation is normal if the ABS warning light comes on for 2 sec onds then goes off If the rear wheel is raced with the vehicle on a suitable stand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on for 2 seconds then goes off The ABS operation is normal if the ABS warning light flas...

Page 30: ...ng distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance be tween yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudde...

Page 31: ... valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine The YCC I system calculates the throttle values from the engine speed activates the intake air funnels with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds Aims and advantage...

Page 32: ...CC I offers higher levels of power across the RPM range Electronically controlled intake length The YCC I system consists of four lightweight plastic resin funnels and each of these is divided into an upper and lower portion Depending upon operating conditions the funnels can be joined to form a single long funnel or split to create a short funnel This change is performed instantaneously by an ele...

Page 33: ... 7 FI CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sensing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 18 Atmospheric pressure sensor 19 Intake funnel servo...

Page 34: ...ric pressure sensor 8 Accelerator position two signals 9 Throttle position two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map 18 Idle speed control 19 Calculated throttle valve opening angle 20 Base map 21 Air funnel position calculation value 22 Intake funnel servo motor...

Page 35: ...n miles and kilo meters To switch the speedometer and odometer tripmeter displays press SELECT for at least two seconds Tripmeters Turn the key to ON Push SELECT to switch the display between the tripmeters TRIP 1 and TRIP 2 in the following order TRIP 1 TRIP 2 TRIP 1 When the fuel amount in the fuel tank decreases to 3 9 L 1 03 US gal 0 86 Imp gal the fuel warning indicator starts flashing and th...

Page 36: ...s This function allows you to adjust the brightness of the tachometer unit panel Meter panel the tachometer needle Needle and the speed ometer and multi function displays Display to suit the outside lighting conditions 1 Push SELECT to highlight Brightness 2 Push RESET then push SELECT to scroll through the functions and to highlight an item 3 Push RESET the brightness level seg ments for the sele...

Page 37: ...ec onds to show that it has been deactivated The indicator light goes off after this menu is exited 5 Push SELECT to scroll to then push RESET to return to the previous menu Setting the r min in relation to the shift timing in dicator light This function allows you to select the engine speed at which the indicator light is activated and deactivated All gears can be set to the same activation deact...

Page 38: ...art flashing then perform steps 4 8 under To set all gears to the same r min in order to set the r min for the individ ual gears TIP After setting r min for individual gears if All is chosen all previously set r min for individual gears return to the default settings of 9000 acti vation and 11000 deactivation 3 Push SELECT to scroll to then push RESET to return to the previous menu Setting the shi...

Page 39: ...nctions This resets ALL settings made to the brightness and shift timing indicator light functions 1 Push SELECT to highlight Display 2 Push RESET 3 Push SELECT to highlight All reset 4 Push RESET then push SELECT to high light Yes 5 Push RESET to reset the brightness and shift timing light indicator values to the factory setting The display returns to the Normal mode TIP To perform further multi ...

Page 40: ...he countdown clock 5 Push SELECT or shift into gear and the countdown clock starts counting down from 5 Simultaneously the shift timing indicator flashes according to the number displayed i e when 5 is displayed the indicator flashes five times when 4 is displayed the indicator flashes four times etc The stop watch starts counting when the countdown clock finishes counting 6 Push SELECT or push th...

Page 41: ... seconds to switch between miles and kilometers Pushing RESET displays the Normal mode for five seconds Pushing SELECT and RE SET for at least three seconds changes the display to the Normal mode To perform further multi function display set tings enter the Select mode again by pushing and holding SELECT and RESET for at least three seconds Resetting the maintenance counters This function allows y...

Page 42: ...ected in any of those circuits the engine trouble warning light comes on and the display indicates a two digit fault code NOTICE ECA2S31064 If the display indicates an fault code the ve hicle should be checked as soon as possible in order to avoid engine damage If the display indicates any fault codes note the code number and check the vehicle Refer to FUEL INJECTION SYSTEM on page 8 33 1 Fault co...

Page 43: ... 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 44: ...rease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 45: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 46: ...elow to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Test coupler adapter 90890 03149 1 19 4 60 4 61 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 36 8 114 8 115 8 123 8 124 8 125 8 129 8 130 8 131 8 132 8 133 8 134 8 135 8 137 8 138 8 139 8 140 Thic...

Page 47: ...2 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 27 4 81 Damper rod holder 24 mm 90890 01328 YM 01328 4 23 4 27 4 48 4 50 Hexagon wrench 41 90890 01525 YM 01525 4 24 4 25 Damper rod holder 90890 01447 YM 01447 4 73 4 74 Fork seal driver 90890 01502 YM A0948 4 74 4 75 Tool name Tool No Illustration Reference pages 41 41 ...

Page 48: ...ool 90890 01235 Universal magneto rotor holder YU 01235 5 14 5 17 5 18 5 21 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 24 5 42 5 77 Valve spring compressor 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 ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 32 Tool name Tool No Ill...

Page 49: ...amer 5 0 mm YM 04099 5 32 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 40 5 41 5 42 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 40 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 46 Universal clutch holder 90890 04086 YM 91042 5 56 5 59 Tool name Tool No Illustration Reference pages ...

Page 50: ...essor 90890 04090 5 109 5 111 Middle drive shaft nut wrench 55 mm 90890 04054 Offset wrench 55 mm YM 04054 5 110 Middle gear backlash tool 90890 04080 5 113 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 4 Tool name Tool No Illustration Reference pages YU 01304 YM 04054 YU 24460 01 ...

Page 51: ...shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 13 Pressure gauge 90890 03153 YU 03153 7 5 7 14 Fuel pressure adapter 90890 03176 YM 03176 7 5 Fuel injector pressure adapter 90890 03210 YU 03210 7 14 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 132 Test harness speed sensor 3P 90890 03208 YU 03208 8 139 Tool name Tool No Illustration Reference pages YU 3398...

Page 52: ...SPECIAL TOOLS 1 43 ...

Page 53: ...TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 23 LUBRICATION POINTS AND LUBRICANT TYPES 2 29 ENGINE 2 29 CHASSIS 2 31 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ENGINE OIL LUBRICATION CHART 2 33 LUBRICATION DIAGRAMS 2 35 COOLING SYSTEM DIAGRAMS 2 43 CABLE ROUTING 2 47 ...

Page 54: ...95 mm 94 3 in Overall width 820 mm 32 3 in Overall height 1190 mm 46 9 in Seat height 775 mm 30 5 in Wheelbase 1700 mm 66 9 in Ground clearance 140 mm 5 51 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel 310 0 kg 683 lb USA 311 0 kg 686 lb California Maximum load 190 kg 419 lb USA 189 kg 417 lb California ...

Page 55: ... amount 5 90 L 6 24 US qt 5 19 Imp qt Without oil filter cartridge replacement 4 30 L 4 55 US qt 3 78 Imp qt With oil filter cartridge replacement 4 70 L 4 97 US qt 4 14 Imp qt Oil pressure 50 0 kPa 1000 r min 0 50 kgf cm 1000 r min 7 3 psi 1000 r min Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 30 L 0 32 US qt 0 26 Imp qt Oil filter Oil filter type Paper Oil pump Oil...

Page 56: ...Manufacturer model NGK CR9EIA Manufacturer model DENSO IU27D Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 28 10 29 00 cm 1 71 1 77 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain gear drive center Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 959 21 972 mm 0 8645 0 8650 in Camshaft journal to camshaft cap clearance 0 ...

Page 57: ...0 0087 0 0114 in Valve dimensions Valve head diameter A intake 33 90 34 10 mm 1 3346 1 3425 in Valve head diameter A exhaust 29 90 30 10 mm 1 1772 1 1850 in Valve face width B intake 1 200 3 100 mm 0 0472 0 1220 in Valve face width B exhaust 1 500 2 700 mm 0 0591 0 1063 in Valve seat width C intake 1 10 1 30 mm 0 0433 0 0512 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 1 10 1 30 mm 0 0433 0 ...

Page 58: ...0 0039 in Valve stem runout 0 010 mm 0 0004 in Valve spring Outer spring Free length intake 40 78 mm 1 61 in Limit 38 74 mm 1 53 in Free length exhaust 40 78 mm 1 61 in Limit 38 74 mm 1 53 in Installed length intake 33 88 mm 1 33 in Installed length exhaust 33 88 mm 1 33 in Spring rate K1 intake 29 00 N mm 2 96 kgf mm 165 59 lb in Spring rate K2 intake 39 01 N mm 3 98 kgf mm 222 75 lb in Spring ra...

Page 59: ...in outside diameter 18 991 19 000 mm 0 7477 0 7480 in Limit 18 971 mm 0 7469 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in Piston ring Top ring Ring type Barrel Dimensions B T 1 00 3 30 mm 0 04 0 13 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 004...

Page 60: ...aring color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Balancer Balancer drive method Gear Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 80 mm 0 1102 in Plate quantity 10 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 9 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring heigh...

Page 61: ...ter element Oil coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 6 5 A Output pressure 324 0 kPa 3 24 kgf cm 47 0 psi Fuel injector Model quantity 1240 4 Throttle body Type quantity EIS48 4 ID mark 2S31 00 USA 2S32 00 California Throttle valve size 50 Throttle position sensor Resistance 1 2 2 8 kΩ Fuel injection sensor Crankshaft position sensor resistance 192 288 Ω...

Page 62: ...emperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in Air induction system Solenoid resistance 20 23 Ω at 20 C 68 F Shaft drive Middle gear backlash 0 05 0 10 mm 0 002 0 004 in Ring gear to thrust washer clearance 0 15 0 25 mm 0 006 0 010 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in ...

Page 63: ...ype Tubeless Size 120 70R18M C 59V Manufacturer model BRIDGESTONE BT028F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 200 50R18M C 76V Manufacturer model BRIDGESTONE BT028R Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition 90 190 kg 198 419 lb ...

Page 64: ...21 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 14 0 mm 0 55 in Caliper cylinder inside diameter 41 30 mm 1 63 in Recommended fluid DOT 4 Clutch Recommended fluid DOT 4 Release cylinder inside diameter 33 6 mm 1 32 in Master cylinder inside diameter 14 0 mm 0 55 in Steering Steering bearing type Taper roller bearing Center to lock angle left 35 0 Center to lock angle right 35 0 Front su...

Page 65: ...7 in Spring free length 166 0 mm 6 54 in Limit 162 0 mm 6 38 in Installed length 159 5 mm 6 28 in Spring rate K1 186 40 N mm 19 01 kgf mm 1064 34 lb in Spring stroke K1 0 0 50 0 mm 0 00 1 97 in Optional spring available No Spring preload adjusting positions Minimum 11 Standard 6 Maximum 1 Rebound damping adjusting positions Minimum 20 click s out Standard 12 click s out Maximum 3 click s out Compr...

Page 66: ...20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage 14 2 14 8 V Rectifier capacity 50 0 A Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Specific gravity 1 31 Ten hour rate amperage 1 12 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 W 55 0 W 1 Auxiliary light 12 V 5 0 W 1 Tail brake light LED...

Page 67: ...type Plane Quantity 1 pc Maximum amperage 3 0 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No Turn signal blinking frequency 75 95 cycles min Fuel sender unit Sender unit resistance full 19 0 21 0 Ω Sender unit resistance empty 139 0 141 0 Ω Starting circuit cut off relay Coil resistance 162 0 198 0 Ω Headlight relay Coil resistance 86 40 105 60 Ω Fuel pump ...

Page 68: ...ELECTRICAL SPECIFICATIONS 2 15 Backup fuse 7 5 A Electronic throttle valve fuse 7 5 A Spare fuse 20 0 A Spare fuse 15 0 A 2 Spare fuse 7 5 A Spare fuse 30 0 A ...

Page 69: ... 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 70: ...eather pipe bolt lower side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Crankcase breather pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Air cut off valve bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Connecting rod bolt M8 8 See TIP Generator rotor bolt M12 1 80 Nm 8 0 m kgf 58 ft lbf Balancer drive gear bolt M10 1 40 Nm 4 0 m kgf 29 ft lbf Camshaft sprocket bolt M7 4 24 Nm 2 4 m kgf 17 ft lbf Camshaft gear bolt ...

Page 71: ...le bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Throttle body joint clamp screw M4 4 3 Nm 0 3 m kgf 2 2 ft lbf Throttle cable locknut M6 2 5 Nm 0 5 m kgf 3 6 ft lbf Fixed intake funnel bolt M6 8 6 Nm 0 6 m kgf 4 3 ft lbf Air filter case screw M5 11 2 5 Nm 0 25 m kgf 1 8 ft lbf Air filter case cover screw M5 8 2 5 Nm 0 25 m kgf 1 8 ft lbf Variable intake funnel holder shaft M6 1 4 5 Nm 0 45 m kgf 3 3 ft lb...

Page 72: ...e TIP l 150mm 5 91 in Crankcase bolt M8 3 24 Nm 2 4 m kgf 17 ft lbf l 110mm 4 33 in Crankcase bolt M8 13 24 Nm 2 4 m kgf 17 ft lbf l 90 mm 3 54 in Crankcase bolt M8 12 24 Nm 2 4 m kgf 17 ft lbf l 65 mm 2 56 in Crankcase bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf l 65 mm 2 56 in Main gallery bolt M20 2 8 Nm 0 8 m kgf 5 8 ft lbf Crankshaft end accessing screw M32 1 2 Nm 0 2 m kgf 1 4 ft lbf Timing mark ac...

Page 73: ... M20 1 95 Nm 9 5 m kgf 68 ft lbf Stake Clutch spring plate retainer bolt M6 6 8 Nm 0 8 m kgf 5 8 ft lbf Clutch boss plate stud bolt M8 6 25 Nm 2 5 m kgf 18 ft lbf Main axle bearing retainer bolt M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Middle drive pinion gear nut M44 1 110 Nm 11 0 m kgf 80 ft lbf Stake Middle drive pinion gear bearing retainer bolt M8 4 24 Nm 2 4 m kgf 17 ft lbf Middle driven pinion gear ...

Page 74: ...h the specified angle 130 140 Cylinder head tightening sequence Cylinder identification sensor bolt M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Upper radiator bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Lower radiator bracket bolt M6 6 7 Nm 0 7 m kgf 5 1 ft lbf Upper lower radiator bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Coolant reservoir and right lower radiator bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lb...

Page 75: ...TENING TORQUES 2 22 Crankcase tightening sequence 30 29 1 2 3 4 5 6 7 8 10 9 11 13 12 14 15 16 17 18 19 21 20 22 23 24 25 26 27 28 A 42 39 41 37 34 33 32 31 35 40 36 38 B A Lower crankcase B Upper crankcase ...

Page 76: ...7 m kgf 5 1 ft lbf Passenger seat bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Passenger seat bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Brake fluid reservoir bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake hose joint holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Left pivot bolt M28 1 100 Nm 10 0 m kgf 72 ft lbf Right pivot bolt M28 1 7 Nm 0 7 m kgf 5 1 ft lbf Pivot bolt locknut M28 1 100 Nm 10 0 m kgf 72 ft lbf ...

Page 77: ...gf 5 1 ft lbf Steering stem nut M22 1 115 Nm 11 5 m kgf 85 ft lbf Handlebar holder bolt M8 4 28 Nm 2 8 m kgf 20 ft lbf Lower ring nut initial tightening torque M28 1 52 Nm 5 2 m kgf 37 ft lbf See TIP Lower ring nut final tightening torque M28 1 18 Nm 1 8 m kgf 13 ft lbf See TIP Lower handlebar holder nut M10 2 32 Nm 3 2 m kgf 23 ft lbf Brake master cylinder holder bolt M6 2 14 Nm 1 4 m kgf 10 ft l...

Page 78: ...sensor lead holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake hose union bolt front brake caliper side M10 1 30 Nm 3 0 m kgf 22 ft lbf Front wheel sensor bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear wheel sensor bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear wheel axle M24 1 98 Nm 9 8 m kgf 71 ft lbf Rear wheel axle pinch bolt M8 2 16 Nm 1 6 m kgf 11 ft lbf Rear wheel sensor holder bolt M6 1 7 Nm 0 7 m kgf 5...

Page 79: ... 5 1 ft lbf Throttle servo motor coupler bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Pivot bolt cover plate bolt M6 10 7 Nm 0 7 m kgf 5 1 ft lbf Side panel bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Side panel and passenger foot rest bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Horn bolt M8 1 16 Nm 1 6 m kgf 11 ft lbf Horn bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Horn cover bolt M5 1 4 Nm 0 4 m kgf 2 9 ft l...

Page 80: ...ft rider footrest bolt M8 2 28 Nm 2 8 m kgf 20 ft lbf Shift arm pinch bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Shift rod locknut shift arm side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Shift rod locknut shift pedal side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Left hand thread Sidestand bolt M8 3 18 Nm 1 8 m kgf 13 ft lbf Dust cover bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Final gear oil filler breather as sembly M20 1 23 Nm...

Page 81: ...t axle is flush with the front fork If necessary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 4 In the order pinch bolt 3 pinc...

Page 82: ...ets and gears Decompression camshaft moving point Water pump impeller shaft Cooling system pipe O rings Oil pump rotors inner and outer Oil strainer Starter idle gear shaft Starter clutch idle gear shaft Starter clutch gear Starter clutch Primary driven gear Long clutch push rod Short clutch push rod Ball Clutch boss nut thread and seat Transmission gears wheel and pinion and collars Main axle and...

Page 83: ...SH001 00 Ring gear splines Ring gear bearing Shaft drive gear oil 9079E SH001 00 Cylinder head cover mating surface Yamaha bond No 1215 Three bond No 1215 Cylinder head cover gasket Yamaha bond No 1215 Three bond No 1215 Crankcase mating surfaces Yamaha bond No 1215 Three bond No 1215 Stator assembly lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant E E E E LS ...

Page 84: ...Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt and metal to metal moving parts Rear brake pedal pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and link contact point Pivot shaft right and left Pivot shaft bearings and collars Pivot shaft oil sea...

Page 85: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 32 ...

Page 86: ... 2 33 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 26 13 14 28 29 27 30 12 36 35 36 38 37 26 36 35 38 36 37 34 33 32 31 31 8 15 12 14 13 8 11 9 10 5 7 6 17 18 19 20 24 25 16 4 3 2 21 20 22 23 1 A B C ...

Page 87: ...il nozzle 2 16 Main gallery 17 Crankshaft journal 1 18 Crankshaft journals 2 3 19 Crankshaft journal 4 20 Crankshaft 21 Connecting rods 1 2 22 Starter idle gear 23 AC magneto 24 Connecting rods 3 4 25 Oil nozzle 3 26 Rear cylinder head 27 Oil pipe 3 28 Drive axle 29 Shift fork 30 Main axle 31 Shift fork guide bar 32 Middle driven pinion gear 33 Oil nozzle 1 34 Oil pipe 35 Intake camshaft 36 Camsha...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 EAS20410 LUBRICATION DIAGRAMS C 1 10 2 3 4 5 6 7 C A A C C D D B B B B D D A A 8 9 10 11 12 12 ...

Page 89: ...ers 2 Exhaust camshaft rear cylinders 3 Intake camshaft rear cylinders 4 Oil pipe 1 5 Timing chain tensioner front cylinders 6 Intake camshaft front cylinders 7 Exhaust camshaft front cylinders 8 Oil cooler 9 Oil filter cartridge 10 Oil pipe 3 11 Drive axle 12 Shift fork guide bar ...

Page 90: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 4 5 2 3 ...

Page 91: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Balancer shaft 2 Main axle 3 Drive axle 4 Intake camshaft 5 Exhaust camshaft ...

Page 92: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 A 2 A 4 3 2 1 ...

Page 93: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Crankshaft 2 Main gallery bolt 3 Oil pipe 2 4 Oil strainer ...

Page 94: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 A A 1 A A 7 6 8 5 4 3 2 ...

Page 95: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil filter cartridge 2 Oil nozzle 3 Oil pump 4 Oil strainer 5 Oil pan 6 Relief valve assembly 7 Oil cooler 8 Oil pipe 1 ...

Page 96: ...OLING SYSTEM DIAGRAMS 2 43 EAS20420 COOLING SYSTEM DIAGRAMS 1 1 2 3 4 6 7 9 8 10 11 7 8 9 9 12 13 5 13 12 10 2 5 2 11 8 D E H 10 12 9 14 13 A B C F G G G G I I H K A F B C D E J B C A E D F H I I G I K J ...

Page 97: ...on the thermostat inlet hose 2 front cylinder side with the rib on the thermostat housing D Align the tape on the ignition coil sub wire harness 2 with the paint mark on the thermostat inlet pipe 1 front cylinder side and then fasten the ignition coil sub wire harness 2 to the thermostat inlet pipe 1 front cylinder side with the plastic holder E Align the paint mark on the thermostat inlet pipe 2 ...

Page 98: ...COOLING SYSTEM DIAGRAMS 2 45 6 1 2 3 4 5 2 3 4 5 7 6 8 9 A B C F E D ...

Page 99: ...he thermostat cover radiator filler pipe B Align the paint mark on the upper radiator inlet pipe with the paint mark on the thermostat outlet hose C Align the paint mark on the upper radiator inlet pipe with the paint mark on the upper radiator inlet hose D Install the upper radiator inlet hose with its paint mark facing outward E Align the paint mark on the left lower radiator inlet hose with the...

Page 100: ... ROUTING C F E I I B B A A D D C C F F E E H H K K J G A F C A A D D C B A H J G K K H I I A B C D E H I J K L M Q R S T U V 14 1 2 6 5 12 13 6 3 4 9 8 16 15 17 10 20 25 21 22 23 24 B C O P N F G 2 5 18 18 10 9 8 7 6 5 11 19 27 26 W E ...

Page 101: ...itch lead and front brake light switch lead with the plastic band The leads may be fastened in any order L Point the end of the plastic locking tie forward and then cut off the excess end of the tie to 2 5 mm 0 08 0 20 in M Insert the projection on the right handlebar switch coupler into the hole in the coupler holder N Route the SELECT RESET button unit lead between the upper radiator inlet pipe ...

Page 102: ...CABLE ROUTING 2 49 A B B A B B A B C D E F F H I 1 2 3 4 4 5 6 7 8 G 6 ...

Page 103: ... C Route the meter assembly 1 lead through the opening in the headlight top cover D Route the clutch hose as shown in the illustration When installing the headlight make sure that the hose is not pinched E Route the left handlebar switch lead as shown in the illustration When installing the headlight make sure that the lead is not pinched Route the right handlebar switch lead in the same way on th...

Page 104: ...CABLE ROUTING 2 51 11 12 14 14 13 15 16 17 18 19 20 21 22 23 24 25 A P 1 G 1 H I 1 2 A 3 4 B 5 6 C 7 8 D 9 E F 10 A Q J K L M N O ...

Page 105: ...e on the starter motor lead E Route the starter motor lead between the frame and the leads air induction system solenoid lead atmospheric pressure sensor lead and radiator fan motor sub wire harness F Make sure that the positioning tape on the radiator fan motor sub wire harness is higher than the front frame as shown in the illustration G Route the meter assembly 2 lead between the main switch le...

Page 106: ...CABLE ROUTING 2 53 A B 7 1 2 3 4 5 6 12 11 13 F E D 10 C G 14 9 8 ...

Page 107: ...een the rear frame and mud guard 1 B Fasten the wire harness at the split in the harness with the holder Face the catch of the holder outward C Insert the projection on the plastic locking tie into the hole in the right side cover from the inside and then fasten the rear brake light switch lead rear wheel sensor lead and O2 sensor lead with the tie D Cross the brake hose hydraulic unit to rear bra...

Page 108: ...CABLE ROUTING 2 55 M D A A B B C C E E D A A B B C C E E A A A B C D E F H I J K L O N P Q R S T U V W 1 2 3 3 4 6 5 5 6 8 9 7 8 9 13 14 15 16 16 17 18 19 19 20 21 22 23 24 G 12 11 10 10 ...

Page 109: ... brake master cylinder to hydraulic unit and to the inside of the air induction system hose air cut off valve to front reed valve cover L When routing the starter motor lead make sure that the lead is not pinched between the upper radiator and the engine M To sub radiator fan motor N Route ignition coil sub wire harness 2 front wheel sensor lead and cylinder identification sensor lead above upper ...

Page 110: ...CABLE ROUTING 2 57 A A A B D E F H 1 2 2 3 4 3 5 6 7 8 9 C 4 5 G ...

Page 111: ...over valve making sure that the hose contacts the valve Position the hose clamp 5 mm 0 20 in from the end of the hose making sure to point the ends of the clamp outward D Install the fuel overflow hose fuel tank breather hose and canister breather hose for California only so that the end of each hose is positioned as shown in the illustration E For California only F Install the hose onto the hose ...

Page 112: ...G 2 59 R 19 20 20 S S 21 22 22 22 U V 23 W 24 G I I G G F F D D A A B B C C E E H A A B B C C D D F F G I H I A B C D E F H I J K L M N O P Q T 1 1 1 2 3 4 5 6 6 6 7 8 8 8 8 9 10 11 11 11 12 13 14 16 15 16 17 18 G ...

Page 113: ...wire harness L shaped guide between the hydraulic unit assembly box and the rear frame J Route the stator coil lead above the fuel hose and fuel pump lead K Fasten the stator coil lead and fuel hose with a plastic locking tie Position the end of the plastic locking tie along the fuel tank Do not cut off the excess end of the plastic locking tie L Insert the projections on the sidestand switch coup...

Page 114: ...CABLE ROUTING 2 61 A A A A A B C 1 2 3 4 5 6 7 8 9 10 11 ...

Page 115: ... signal light lead 9 License plate light coupler yellow 10 Rectifier regulator 11 Canister purge hose for California only A Route the tail brake light lead and rear right turn signal light lead through the hole in the mud guard rubber cover B Route the license plate light lead and rear left turn signal light lead through the hole in the mud guard rubber cover C Make sure that the plastic locking t...

Page 116: ...CABLE ROUTING 2 63 D B B C C E E A D A B B C C E E A B B C D D E F 1 1 2 3 4 4 9 8 5 6 7 10 11 12 12 13 13 14 13 12 13 11 10 ...

Page 117: ...ery lead to wire harness A To wire harness B To positive battery terminal C Route the leads that branch off from the wire harness through the slit in the battery box heat shield D Route the main fuse lead and starter relay lead between the positive battery lead and the battery box E Wrap the battery box heat shield around the brake hose front brake master cylinder to hydraulic unit and brake hose ...

Page 118: ...CABLE ROUTING 2 65 B A 1 2 3 4 5 5 7 6 8 9 C C 10 10 10 10 11 11 A A 14 11 12 13 13 12 15 D 12 D E E E ...

Page 119: ... coupler 10 Negative pressure hose 11 Canister purge hose California only 12 Plastic locking tie 13 Plastic band 14 Plastic band California only 15 Plastic locking tie California only A Forward B To coolant temperature sensor C Make sure that the canister purge hoses are not pinched between the cylinder head covers and the throttle valve shafts D Position the plastic locking ties as shown in the i...

Page 120: ...CABLE ROUTING 2 67 B A C C B A C C A B C D E F G H I J 1 2 1 2 5 1 2 3 5 3 4 5 ...

Page 121: ...9 93 C Fasten the brake hose hydraulic unit to rear brake caliper and brake hose rear brake master cylinder to hydraulic unit with the holder D To rear brake caliper E To rear brake master cylinder F 3 7 G 30 34 H To left front brake caliper I To front brake master cylinder J Be sure to position the brake hose hydraulic unit to rear brake caliper and brake hose rear brake master cylinder to hydrau...

Page 122: ...CABLE ROUTING 2 69 A A B B B B A A A A B C D E F G G H I J K L M N O 1 2 2 3 3 3 3 3 3 4 4 5 5 6 6 7 7 7 7 ...

Page 123: ...nal position light lead front left turn signal position light lead and grommet on the brake hose front brake master cylinder to hydraulic unit with the holder J Face the catch of the holder rearward K Fasten the front left turn signal position light lead to the brake hose and front left turn signal position light lead guide with plastic locking ties Align the plastic locking ties with the cutouts ...

Page 124: ...CABLE ROUTING 2 71 ...

Page 125: ...E OIL 3 11 MEASURING THE ENGINE OIL PRESSURE 3 12 ADJUSTING THE CLUTCH LEVER 3 12 CHECKING THE CLUTCH FLUID LEVEL 3 13 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3 13 REPLACING THE AIR FILTER ELEMENT 3 14 CHECKING THE THROTTLE BODY JOINTS 3 15 CHECKING THE FUEL LINE 3 15 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 15 CHECKING THE CRANKCASE BREATHER HOSE 3 16 CHECKING THE EXHAUST SYSTEM 3 16 CHECKING THE ...

Page 126: ...REAR SUSPENSION 3 28 CHECKING THE SWINGARM PIVOT 3 28 ADJUSTING THE FRONT FORK LEGS 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 29 CHECKING THE TIRES 3 31 CHECKING THE WHEELS 3 32 CHECKING THE SIDESTAND 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 LUBRICATING THE LEVERS 3 33 LUBRICATING THE PEDALS 3 33 LUBRICATING THE SIDESTAND 3 33 LUBRICATING THE REAR SUSPENSION 3 33 LUBRICATING THE SWING...

Page 127: ......

Page 128: ...00 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Clean Replace every 12000 mi 19000 km or 18 months Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchroniza...

Page 129: ...pply lithium soap based grease lightly 14 Clutch lever pivot shaft Apply silicone grease lightly 15 Shift pedal pivot shaft Apply lithium soap based grease lightly 16 Sidestand pivot Check operation Apply lithium soap based grease lightly 17 Sidestand switch Check operation and replace if necessary 18 Front fork Check operation and for oil leakage Replace if necessary 19 Shock absorber assembly Ch...

Page 130: ...ired Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged 25 Final gear oil Check oil level and for oil leak age Change at initial 600 mi 1000 km or 1 month and thereaf ter every 16000 mi 25000 km or 24 months Change Change 26 Front ...

Page 131: ...ance Out of specification Adjust TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence Piston 1 TDC a Position piston 1 at TDC by turning the crankshaft counterclockwise until the T1 mark a on the generator rotor is aligned with the stationary pointer b on the generator cover b Check that the punch mark c punch mark d and 1 mark e...

Page 132: ...Position piston 2 at TDC b Turn the crankshaft almost 2 3 of a turn 223 degrees counterclockwise until the F mark a on the generator rotor is aligned with the stationary pointer b on the generator cover c Measure the valve clearance with a thickness gauge 4 Remove Camshafts TIP Refer to CAMSHAFTS on page 5 9 When removing the timing chain and cam shafts fasten the timing chain with a wire to re tr...

Page 133: ...thickness is 1 55 mm 0 061 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 55 mm 0 061 in 0 03 mm 0 001 in 1 58 mm 0 062 in The valve pad number is 158 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the avai...

Page 134: ...se the removal procedure EAS20571 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 Air induction system Exhaust system Canister purge hoses for California only Breather hoses Checking the throttle body synchronization 1 Stand the vehicle on a level surface TIP Plac...

Page 135: ... at idle and the throttle bodies may not operate properly TIP Do not use a rear cylinder throttle body as the standard TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed clean or re place the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 k...

Page 136: ...k plug cap 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug...

Page 137: ...es the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for se...

Page 138: ...n the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Check Engine oil drain bolt gasket Damage Replace 7 Install Engine oil drain bolt along with the gasket 8 Fill Crankcase with the specified amount of the recom mended engine oil 9 Install Engine oil filler cap 10 Start the engine warm it up for several min utes and then tur...

Page 139: ...il pressure at the following conditions Out of specification Adjust 6 Install Main gallery bolt EAS20860 ADJUSTING THE CLUTCH LEVER 1 Adjust Clutch lever position distance a from the handlebar grip to the clutch lever a While pushing the clutch lever forward turn the adjusting dial 1 until the clutch lever is in the desired position TIP Be sure to align the setting on the adjusting dial with the a...

Page 140: ...tic parts Therefore always clean up any spilt clutch fluid immediately TIP In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal 4 Install Clutch master cylinder reservoir diaphragm Clutch master cylinder reservoir diaphragm holder Clutch master cylinder reservoir cap Refer to CLUTCH on page 5 48 EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTE...

Page 141: ...s have disappeared from the clutch fluid in the plastic hose j Tighten the bleed screw to specification k Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 13 WARNING EWA13010 After bleeding the hydraulic clutch system check the clutch operation EAS20961 REPLACING THE AIR FILTER ELEMENT 1 Remove Top cover Intake duct assemblies ECU tray Refer t...

Page 142: ... Refer to AIR FILTER CASE on page 7 6 Throttle bodies Refer to THROTTLE BODIES on page 7 11 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Throttle bodies Refer to THROTTLE BODIES on page 7 11 Air filter case Refer to AIR FILTER CASE on page 7 6 Intake duct assemblies Top cover Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL LINE 1 Remove Rider seat Refer to GENERAL...

Page 143: ...TIP The rear exhaust pipe cannot be removed with out removing the engine 4 Check Tightening torque Front exhaust pipe nuts 12 Left front exhaust pipe and right front exhaust pipe bolt 13 Front exhaust pipe and exhaust chamber bolts 14 Exhaust chamber and muffler bolts 15 Rear exhaust pipe and exhaust chamber bolts 16 Muffler bolts 17 Exhaust chamber bolts 18 Exhaust chamber bracket front side bolt...

Page 144: ...breather hose 4 Cracks damage Replace 3 Install Left side cover Refer to GENERAL CHASSIS on page 4 1 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation a Activate the diagnostic mode and select the diagnostic code No D 53 Refer to FUEL INJECTION SYSTEM on page 8 33 b Set the engine stop switch to c Turn the main switch to ON d Check that the EXUP va...

Page 145: ...coolant level should be between the min imum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However i...

Page 146: ...l cooler Oil cooler outlet hose Oil cooler inlet hose Water pump outlet pipe Water pump inlet pipe Cracks damage Replace Refer to RADIATORS on page 6 1 OIL COOLER on page 6 5 THERMOSTAT on page 6 7 and WATER PUMP on page 6 11 3 Install Front exhaust pipes Refer to ENGINE REMOVAL on page 5 1 Throttle bodies Refer to THROTTLE BODIES on page 7 11 EAS21130 CHANGING THE COOLANT 1 Remove Top cover Right...

Page 147: ...d with special care WARNING EWA13040 If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention NOTICE ECA13480 Adding water instead of coolant lowers the antifreeze content of the coolant If water ...

Page 148: ... Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 18 TIP Before checking the coolant level wait a few minutes until the coolant has settled 16 Install Right intake duct assembly Top cover Refer to GENERAL CHASSIS on page 4 1 EAS2S31009 CHECKING THE AIR INDUCTION SYSTEM Refer to CHECKING THE AIR INDUCTION SYSTEM on page 7 23 a ...

Page 149: ... TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Release the backrest 3 Remove Passenger seat Refer to GENERAL CHASSIS on page 4 1 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage a...

Page 150: ...ck Brake hose holders Loose Tighten the holder bolts 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 29 REAR BRAKE on page 4 41 and ABS AN TI LOCK BRAKE SYSTEM on page 4 55 EAS2S31011 CHECKING THE BRAKE LIGHT SWITCHES 1 Check Front brake light switch operation Rear brake light switch operati...

Page 151: ...re when the tiny bubbles in the hose have disappeared 1 Bleed ABS a Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the...

Page 152: ...ift rod length a Loosen both locknuts 1 b Turn the adjusting bolt 2 in direction a or b until the specified installed shift rod length is obtained c Tighten both locknuts to specification d Make sure the installed shift rod length is within specification EAS21460 CHECKING THE FINAL GEAR OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle...

Page 153: ...along with the gasket EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust t...

Page 154: ...old the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 78 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it fa...

Page 155: ...IVOT 1 Measure Swingarm side play Swingarm vertical movement Refer to REMOVING THE SWINGARM on page 4 89 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA2S31005 Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability Securely support the vehicle so that there is no danger of it f...

Page 156: ...NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Turn the adjusting knob 1 in direction a or b Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Standard 12 click s out Maximum 1 click s out With the adjusting k...

Page 157: ... suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 11 Standard 6 Maximum 1 1 b a 5 4 3 2 1 11 6 7 10 9 8 Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 20 click s out Standard 12 click s out Maximum ...

Page 158: ...aches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Compression damping adjusting positions Minimum 12 click s out Standard 10 click s out Maximum 1 click s out With the adjusting knob fully turned in b a 1 Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Lo...

Page 159: ...proved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with...

Page 160: ... levers EAS21710 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension EAS2S31016 LUBRICATING THE SWINGARM PIVOT 1 Lubr...

Page 161: ...ight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA2S31075 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach Head...

Page 162: ...hat all lights come on Refer to INSTRUMENT AND CONTROL FUNCTIONS in Owner s manual Faulty Refer to CHECKING THE SWITCHES on page 8 121 and CHECK ING THE BULBS AND BULB SOCKETS on page 8 124 EAS2S31020 CHECKING THE SWITCHES Refer to CHECKING THE SWITCHES on page 8 121 Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left b a 1 ...

Page 163: ...CHECKING THE REAR WHEEL 4 24 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 24 ASSEMBLING THE REAR WHEEL 4 24 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 26 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 26 FRONT BRAKE 4 29 INTRODUCTION 4 34 CHECKING THE FRONT BRAKE DISCS 4 34 REPLACING THE FRONT BRAKE PADS 4 35 REMOVING THE FRONT BRAKE CALIPERS 4 36 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 36...

Page 164: ... 4 57 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 58 HYDRAULIC UNIT OPERATION TESTS 4 59 TRIAL RUN 4 62 HANDLEBAR 4 63 REMOVING THE HANDLEBAR 4 65 CHECKING THE HANDLEBAR 4 65 INSTALLING THE HANDLEBAR 4 65 FRONT FORK 4 68 REMOVING THE FRONT FORK LEGS 4 72 DISASSEMBLING THE FRONT FORK LEGS 4 72 CHECKING THE FRONT FORK LEGS 4 73 ASSEMBLING THE FRONT FORK LEGS 4 73 INSTALLING THE FRONT FORK LEGS 4 77 STE...

Page 165: ...ON AND CHECKING THE SHAFT DRIVE FOR LEAKS 4 96 MEASURING THE FINAL GEAR BACKLASH 4 96 ADJUSTING THE FINAL GEAR BACKLASH 4 97 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 98 REMOVING AND INSTALLING THE BEARING 4 99 ASSEMBLING THE FINAL DRIVE ASSEMBLY 4 99 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 100 CHECKING THE DRIVE SHAFT 4 103 INSTALLING THE FINAL DRIVE ASSEMBLY 4 103 ...

Page 166: ...covers and rear fender Order Job Parts to remove Q ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Left side cover 1 4 Right side cover 1 5 Rear fender 1 For installation reverse the removal proce dure 3 1 2 5 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 167: ...ler 1 2 Owner s tool kit 1 3 Left side cover inner panel 1 4 Relay unit 1 5 Fuse box 1 1 6 Turn signal hazard relay 1 7 O2 sensor coupler 1 Disconnect 8 Rear brake light switch coupler 1 Disconnect 9 Rear wheel sensor coupler 1 Disconnect 10 Right side cover inner panel 1 11 Tail brake light coupler 1 Disconnect 12 Tail brake light assembly 1 13 Rectifier regulator 1 2 1 3 7 9 8 4 6 5 10 13 11 12 ...

Page 168: ... For installation reverse the removal proce dure Removing the side cover inner panels tail brake light assembly and rear turn signal light assembly Order Job Parts to remove Q ty Remarks 2 1 3 7 9 8 4 6 5 10 13 11 12 16 17 14 15 15 LT LT LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 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 ...

Page 169: ...G THE ABS TEST COUPLER 1 Install ABS test coupler 1 TIP Route the ABS test coupler lead through the slot a in the left side cover inner panel Make sure that the ABS test coupler clasp fac es inward toward the left side cover inner pan el a 1 ...

Page 170: ...ly Mufflers Exhaust chamber Refer to ENGINE REMOVAL on page 5 1 1 Seat lock cable 1 2 Spring preload adjusting knob 1 3 Left passenger footrest 1 4 Gas tank rear shock absorber assembly 1 5 Right passenger footrest 1 6 Mudguard 2 1 For installation reverse the removal proce dure 4 6 2 3 5 4 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 26 Nm 2 6 m k...

Page 171: ...cover bracket 2 6 Meter assembly 2 coupler 2 Disconnect 7 Meter assembly 2 1 8 Main switch cover 1 9 Meter assembly 2 bracket 1 10 Main switch bezel 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 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 7 Nm 0 7 m kgf 5 1 ft...

Page 172: ...t intake duct inner plate 1 3 Left intake grill 1 4 Left intake dust filter 2 5 Right intake duct 1 6 Right intake duct inner plate 1 7 Right intake grill 1 8 Right intake dust filter 2 For assembly reverse the disassembly pro cedure New New LT LT New 4 Nm 0 4 m kgf 2 9 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R 6 5 3 2 1 4 7 8 ...

Page 173: ...front side of the top cover bracket and then on the rear side 2 Install Top cover a Install the top cover bolts 1 temporarily b Tighten top cover bolts 1 and 2 T R Top cover bracket bolt 7 Nm 0 7 m kgf 5 1 ft lbf LOCTITE T R Top cover bolt 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Top cover bolt 2 7 Nm 0 7 m kgf 5 1 ft lbf 2 2 1 2 ...

Page 174: ...sconnect 3 ECU coupler 2 Disconnect 4 ECU engine control unit 1 5 Lean angle sensor coupler 1 Disconnect 6 Lean angle sensor 1 7 Main fuse 1 8 Starter relay coupler 1 Disconnect 9 Starter relay 1 10 ECU tray 1 11 Battery cover 1 12 Battery 1 13 Battery seat 1 14 Battery box 1 For installation reverse the removal proce dure LT LT 3 3 4 5 8 10 9 1 2 13 7 6 12 11 14 LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T...

Page 175: ...y 2 TIP Install the battery seat as shown in the illustra tion 2 Install Positive battery lead 1 Negative battery lead 2 NOTICE ECA2S31067 First connect the positive battery lead 1 then the negative battery lead 2 TIP Pass the positive battery lead through the guide on the battery box 1 2 1 2 a ...

Page 176: ...LECT RESET button unit coupler 1 Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Headlight coupler 1 Disconnect 6 Meter assembly 1 1 7 Meter assembly 1 bracket 2 8 Headlight top cover 1 9 Headlight side cover 2 10 Headlight lens unit 1 For installation reverse the removal proce dure 1 7 7 8 9 6 4 5 9 10 2 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 177: ...ront brake caliper 2 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 11 Front brake disc 2 For installation reverse the removal proce dure 4 4 3 10 8 9 7 5 5 5 6 11 11 1 2 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 21 Nm 2 1 ...

Page 178: ... wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Oil seal 1 3 Front wheel sensor rotor 1 4 Wheel bearing 2 5 Spacer 1 For assembly reverse the disassembly pro cedure New New New 1 4 5 4 2 3 5 LT LS LS 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 179: ...21910 DISASSEMBLING THE FRONT WHEEL NOTICE ECA2S31008 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seals Wheel bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a f...

Page 180: ...nets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor i...

Page 181: ... Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new wheel bearing right side NOTICE ECA2S31011 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer rac...

Page 182: ...heel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy sp...

Page 183: ... smooth ly TIP Lubricate the front wheel axle bolt seats with lith ium soap based grease a Insert the front wheel axle from the left side and tighten it with the front wheel axle bolt from the right side to 81 Nm 8 1 m kgf 59 ft lbf b In the order pinch bolt 2 pinch bolt 1 pinch bolt 2 tighten each bolt to 21 Nm 2 1 m kgf 15 ft lbf without performing temporary tightening c Check that the left end ...

Page 184: ...e sensor electrode for foreign materials Install the front wheel sensor lead holder with the UP mark facing up and to the inside NOTICE ECA2S31014 Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the inner sensor rotor and wheel sensor To route the front wheel sensor lead refer to CABLE ROUTING on page 2 47 WARNING EWA13500 Make sure the brake hose is rou...

Page 185: ... bolt 2 4 Rear brake caliper 1 5 Brake pad shim 1 6 Brake pad insulator 1 Left side only 7 Rear brake pad 2 8 Brake pad shim 1 9 Brake pad support 2 10 Rear wheel axle pinch bolt 2 Loosen 11 Rear wheel axle 1 12 Rear brake caliper bracket 1 13 Rear wheel 1 14 Rear wheel sensor housing 1 LT LS S S 13 16 14 15 2 12 5 11 1 10 5 6 8 3 9 4 7 9 23 Nm 2 3 m kgf 17 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R...

Page 186: ...re Removing the rear wheel brake disc wheel sensor and sensor housing Order Job Parts to remove Q ty Remarks LT LS S S 13 16 14 15 2 12 5 11 1 10 5 6 8 3 9 4 7 9 23 Nm 2 3 m kgf 17 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 98 Nm 9 8 m kgf 71 ft Ibf T R ...

Page 187: ...ring 1 8 Spacer 1 9 Spacer 1 10 Rear wheel ring plate 1 11 Rear wheel ring 1 12 Oil seal 1 13 Bearing retainer 1 14 Rear wheel sensor rotor 1 15 Wheel bearing 1 16 Bearing 1 For assembly reverse the disassembly pro cedure New New New LS LS LT LT LT LT LT LT LT LS 1 3 5 4 6 7 8 9 10 11 12 5 5 13 15 14 16 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 80...

Page 188: ...heel sensor housing otherwise the sensor could be damaged 3 Remove Rear wheel axle 1 TIP Remove the rear wheel axle with the damper rod holder 24 mm 2 4 Remove Rear wheel TIP Move the rear wheel to the right to separate it from the final drive assembly EAS2S31021 DISASSEMBLING THE REAR WHEEL NOTICE ECA2S31008 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the whe...

Page 189: ...nnot be disassem bled Do not attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 2 Check Rear wheel sensor rotor Refer to...

Page 190: ...e bearing retainer 1 with a hexa gon wrench 41 2 NOTICE ECA2S31020 The bearing retainer has left handed threads To tighten the retainer turn it coun terclockwise 5 Install Rear wheel drive hub 1 Dust seal Rear wheel drive hub stopper 2 Dust cover TIP Install the rear wheel drive hub so that the pro jection a fits between the ends b of the rear wheel drive hub stopper Installed depth of bearing a 9...

Page 191: ...AR BRAKE DISC on page 4 47 3 Lubricate Oil seal lips 4 Install Rear wheel sensor housing Rear wheel Rear brake caliper bracket Rear wheel axle TIP Do not install the brake pad supports brake pads brake pad insulator brake pad shims and brake caliper Align the slot a of the rear wheel sensor hous ing 1 with the projection b of the rear brake caliper bracket 2 and then assemble them Fit the brake to...

Page 192: ...ake pads Brake caliper retaining bolts Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4 47 7 Measure TIP Measure the distance a only if the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and wheel sensor housing 2 Out of specification Reinstall the bearing or replace the wheel sensor rotor T R Rear wheel axle 98 Nm 9 8 m kgf ...

Page 193: ...he rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 9 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly Distance a between the wheel sensor rotor and wheel sensor housing 29 2 29 5 mm 1 15 1 16 in T R Rear wheel sensor bolt 7 Nm 0 7 m kg 5 1 ft lb 1 2 a ...

Page 194: ...heel sensor lead holder 1 Left side only 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Front brake pad 4 7 Bleed screw 1 Left brake caliper side 8 Bleed screw 1 Right brake caliper side For installation reverse the removal procedure 7 8 2 3 4 3 4 5 6 6 New 1 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R ...

Page 195: ...phragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake light switch 1 8 Brake hose union bolt 1 9 Brake hose gasket 2 10 Brake hose front brake master cylinder to hy draulic unit 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 For installation reverse the removal proce dure 4 5 12 11 ...

Page 196: ...4 31 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 S 1 2 1 New New ...

Page 197: ...olt 1 3 Brake hose gasket 1 Left side only 4 Brake hose gasket 2 5 Brake hose left front brake caliper to right front brake caliper 1 Left brake caliper side 6 Brake hose left front brake caliper to right front brake caliper 1 Right brake caliper side 7 Brake hose hydraulic unit to left front brake cal iper 1 Left side only 8 Front brake caliper 1 For installation reverse the removal procedure 2 6...

Page 198: ...rake pad spring 2 4 Front brake pad 4 5 Brake caliper piston 6 6 Brake caliper piston dust seal 6 7 Brake caliper piston seal 6 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side For assembly reverse the disassembly procedure 2 5 5 2 3 9 1 4 4 1 3 8 5 5 7 7 New 7 New 7 New 6 New New New 6 New 6 New New 6 7 New S S S S BF BF BF S BF BF S 6 New 5 Nm 0 5 m kgf 3 6 ft Ibf...

Page 199: ...e applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 12 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 o...

Page 200: ...t a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad springs TIP Always install new brake pads and new brake pad springs 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 ...

Page 201: ...liper to right front brake caliper Brake hose hydraulic unit to left front brake caliper TIP Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston dust seals 2 Brake caliper piston seals 3 a Blow compres...

Page 202: ...E FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper temporarily Brake hose gaskets Brake hose hydraulic unit to left front brake caliper 1 Brake hose left front brake caliper to right front brake caliper 2 Brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE RO...

Page 203: ... 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 ABS on page 3 24 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 7 C...

Page 204: ...nts EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 TIP Align the mating surfaces of the brake master cylinder holder with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install Brake hose gaskets Brake hose front brake master cylinder to hydraulic unit 1 Brake hose union bolt 2 WARNING EWA13...

Page 205: ...nter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 24 5 Check Brake fluid level Below the minimum l...

Page 206: ...per retaining bolt 2 2 Rear brake caliper 1 3 Brake pad shim 1 4 Brake pad insulator 1 Left side only 5 Rear brake pad 2 6 Brake pad shim 1 7 Brake pad support 2 For installation reverse the removal proce dure 3 4 6 1 1 7 2 5 5 7 S S 27 Nm 2 7 m kgf 19 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R ...

Page 207: ...reservoir 1 5 Brake fluid reservoir hose 1 6 Brake pedal 1 7 Rear brake light switch coupler 1 Disconnect 8 Brake hose union bolt 1 9 Brake hose gasket 2 10 Brake hose rear brake master cylinder to hy draulic unit 1 11 Right rider footrest assembly 1 12 Rear brake light switch bracket 1 13 Brake pedal pivot shaft spring 1 1 8 9 11 10 2 3 4 LT LT LT 5 7 12 14 16 17 6 15 13 New New 7 Nm 0 7 m kgf 5 ...

Page 208: ...reverse the removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 8 9 11 10 2 3 4 LT LT LT 5 7 12 14 16 17 6 15 13 New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R LS 28 Nm 2 8 m kgf 20 ft Ibf T R ...

Page 209: ...e master cylinder Order Job Parts to remove Q ty Remarks 1 Rear brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 2 3 1 S New 16 Nm 1 6 m kgf 11 ft Ibf T R ...

Page 210: ...e caliper retaining bolt 2 6 Rear brake caliper 1 7 Brake pad shim 1 8 Brake pad insulator 1 Left side only 9 Rear brake pad 2 10 Brake pad shim 1 11 Brake pad support 2 12 Rear wheel axle pinch bolt 2 Loosen 13 Rear wheel axle 1 14 Rear brake caliper bracket 1 For installation reverse the removal proce dure 13 1 6 5 12 2 3 4 5 14 11 7 8 9 9 10 New S S LS 11 S S 98 Nm 9 8 m kgf 71 ft Ibf T R 30 Nm...

Page 211: ...liper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 3 4 New 2 New BF S 6 Nm 0 6 m kgf 4 3 ft Ibf T R ...

Page 212: ...e galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 34 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 34 5 Adjust Brake disc deflection Refer to ...

Page 213: ...vel mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 24 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake ...

Page 214: ...ns Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA2S31008 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket...

Page 215: ...n 3 on the swing arm into the slot c on the rear brake caliper bracket After assembling the rear wheel sensor hous ing and the rear brake caliper bracket make sure that the projection d on the housing is aligned with the projection e on the bracket NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor 2...

Page 216: ...use the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and coul...

Page 217: ...tion Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Cracks damage Replace 4 Check Brake hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricat...

Page 218: ...d poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may dam...

Page 219: ... pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 24 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 a ...

Page 220: ...ose hydraulic unit to left front brake caliper 4 Brake hose front brake master cylinder to hydraulic unit 5 ABS warning light 6 Brake hose left front brake caliper to right front brake caliper 7 Front wheel sensor 8 Front wheel sensor rotor 9 Brake hose rear brake master cylinder to hydraulic unit 10 Brake hose hydraulic unit to rear brake caliper 11 Rear wheel sensor 12 Rear wheel sensor rotor ...

Page 221: ...ke cal iper 1 Disconnect 4 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 5 Brake hose hydraulic unit to rear brake caliper 1 Disconnect 6 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 7 Fuse box 2 1 8 Hydraulic unit assembly 1 9 Hydraulic unit assembly box 1 For installation reverse the removal proce dure 2 3 5 6 7 8 9 4 1 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 222: ...pecified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Pull the coupler ejection slider up to disconnect the ABS ECU coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA2S31031 When removing the brake hoses cover the area around the hydraulic unit assembly to catch any spilt brake fluid Do not allow the bra...

Page 223: ... b in the battery box bracket 4 Tighten Brake hose flare nuts Brake hose holder bolt NOTICE ECA2S31027 If the brake hose flare nut does not turn eas ily replace the hydraulic unit assembly brake hoses and related parts as a set TIP First tighten the brake hose flare nut then the brake hose holder bolt Do not bend the pipe section of the brake hose when tightening the brake hose flare nuts When tig...

Page 224: ...odes Refer to D 1 DE LETING THE FAULT CODES on page 8 114 10 Perform a trial run Refer to TRIAL RUN on page 4 62 EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Hydraulic unit operatio...

Page 225: ...are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly If the operation of the hydraulic unit is normal delete all of the fault codes Hydraulic unit operation test 2 WARNING EWA13120 Securely support the vehicle so that there is no ...

Page 226: ...ction is generated in the brake lever 1 0 5 second after the brake lever and the brake pedal are operated simultaneously and continues for approxi mately 1 5 seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in the brake lever it...

Page 227: ...n the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulsating action is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 13 Turn the main switch to OFF 14 Remove the test coupler adapter from the ABS test coupler 15 Turn the ...

Page 228: ...using 2 8 Throttle cable 2 Disconnect 9 Right grip end 1 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect 12 Clutch master cylinder holder 1 13 Clutch master cylinder assembly 1 14 Left handlebar switch 1 15 Left grip end 1 16 Handlebar grip 1 1 5 3 17 14 11 1 2 2 4 18 4 6 6 8 7 13 15 16 14 12 7 10 19 21 20 9 LS LT LS LT LS 32 Nm 3 2 m kgf 23 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 28 Nm ...

Page 229: ...tallation reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 5 3 17 14 11 1 2 2 4 18 4 6 6 8 7 13 15 16 14 12 7 10 19 21 20 9 LS LT LS LT LS 32 Nm 3 2 m kgf 23 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R ...

Page 230: ...RESET button unit 1 Handlebar 2 Upper handlebar holder NOTICE ECA2S31030 First tighten the bolts on the front side of the handlebar holder and then on the rear side TIP Align the pin a on the left lower handlebar hold er with the hole b on the handlebar 3 Tighten Lower handlebar holder nuts 4 Install Handlebar grip 1 Left grip end 2 a Apply a thin coat of rubber adhesive onto the end of the left h...

Page 231: ... mark b on the handlebar First tighten the upper bolt then the lower bolt 7 Install Throttle grip Throttle cables Throttle cable housings 1 TIP Align the projection a on the throttle cable housing with the hole b in the handlebar 8 Install Right handlebar switch 1 TIP Align the projection a on the right handlebar switch with the hole b on the handlebar 9 Install Front brake master cylinder assembl...

Page 232: ...master cylinder holder with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 9 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in 1 a ...

Page 233: ...lector 2 7 Front fender inner bracket left 1 8 Front fender inner bracket right 1 9 Front fender 1 10 Headlight lower bracket 1 11 Upper bracket pinch bolt 1 Loosen 12 Cap bolt 1 Loosen 13 Turn signal light pinch bolt 1 Loosen 13 12 15 1 5 4 6 2 3 7 8 6 9 10 3 2 4 11 14 LT 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 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 234: ...ob Parts to remove Q ty Remarks 13 12 15 1 5 4 6 2 3 7 8 6 9 10 3 2 4 11 14 LT 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 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 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R LT ...

Page 235: ...amper adjusting rod 1 5 Spacer 1 6 Spring sleeve 1 7 Spring seat 1 8 Fork spring 1 9 Dust seal 1 10 Oil seal clip 1 11 Damper rod assembly bolt 1 12 Copper washer 1 13 Damper rod assembly 1 14 Oil flow stopper 1 15 Spring 1 16 Inner tube 1 1 2 New LS 4 5 6 7 8 New 9 New 10 New 17 18 New 19 15 14 13 New 20 21 16 LS New 12 11 LT LT 3 35 Nm 3 5 m kgf 25 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 236: ... 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 1 2 New LS 4 5 6 7 8 New 9 New 10 New 17 18 New 19 15 14 13 New 20 21 16 LS New 12 11 LT LT 3 35 Nm 3 5 m kgf 25 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 237: ...WA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 3 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Hold the locknut 1 and loosen the cap bolt 2 2 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a ...

Page 238: ...r tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod assembly Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA14200 The front fork leg has a built ...

Page 239: ...1 on the damper rod assembly 2 Install Inner tube bushing 1 Oil flow stopper 2 Damper rod assembly 3 NOTICE ECA2S31032 Allow the damper rod assembly to slide slowly down the inner tube 4 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 3 Lubricate Inner tube s outer surface 4 Tighten Damper rod assembly bolt TIP While holding the damper rod assembly wit...

Page 240: ...l clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver 2 9 Fill Front fork leg with the specified amount of the recom mended fork oil NOTICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any ...

Page 241: ... the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 14 Install Fork spring TIP Install the fork spring so that the end A shown in the illustration is facing up 15 Install Locknut 1 Damper adjusting rod 2 C...

Page 242: ...bolt 4 WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP Tighten the air intake duct assembly rear brack et bolts to the specified torque twice Be sure to tighten the front bolt before tightening the rear bolt each time and do not loosen the bolts after tightening them to the specified torque 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT...

Page 243: ...ct 3 Left handlebar switch coupler 1 4 Front right turn signal position light coupler 1 Disconnect 5 Front left turn signal position light coupler 1 Disconnect 6 Front brake light switch coupler 1 Disconnect 7 Right handlebar switch coupler 1 8 SELECT RESET button unit lead 1 9 Coupler holder 1 10 Intake air temperature sensor 1 11 Front right turn signal position light 1 12 Front left turn signal...

Page 244: ...tallation reverse the removal proce dure Removing the coupler holder and brake hose holder Order Job Parts to remove Q ty Remarks 2 3 10 5 4 6 9 12 11 1 8 7 13 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 ...

Page 245: ... 1 5 Rubber washer 1 6 Lower ring nut 1 7 Upper bearing cover 1 8 Upper bearing 1 9 Lower bracket 1 10 Lower bearing 1 11 Dust seal 1 12 Upper bearing race 1 13 Lower bearing race 1 For installation reverse the removal proce dure LS 1 2 5 3 4 6 7 8 12 13 10 11 9 1st 52 Nm 5 2 m kgf 37 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf T R 115 Nm 11 5 m kgf 85 ft lbf T R ...

Page 246: ...aring races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer 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 Wheneve...

Page 247: ... page 3 26 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 68 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease T R Steering stem nut 115 Nm 11 5 m kgf 85 ft lbf ...

Page 248: ...knut Wash er Nut Bolt 1 1 1 1 7 Connecting arm and relay arm locknut Wash er Nut Bolt 1 2 1 1 8 Connecting arm 1 9 Collar 1 10 Oil seal 2 11 Bearing 2 2 2 4 1 5 2 6 6 8 9 7 7 7 7 3 13 18 18 16 15 15 14 12 20 12 3 17 19 17 11 10 10 11 LS New New New New New New LT LS LS LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 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...

Page 249: ...s 2 2 4 1 5 2 6 6 8 9 7 7 7 7 3 13 18 18 16 15 15 14 12 20 12 3 17 19 17 11 10 10 11 LS New New New New New New LT LS LS LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 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 32 ft Ibf T R 45 Nm 4 5 m kgf 32 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 48 ...

Page 250: ...ll a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 45 55 mm 1 77 2 17 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place...

Page 251: ...ting arm and relay arm and connecting arm and swingarm bolts b Tighten the connecting arm and relay arm and connecting arm and swingarm nuts T R Relay arm bracket bolt 48 Nm 4 8 m kgf 35 ft lbf Recommended lubricant Lithium soap base grease 1 a Installed depth a 4 6 5 6 mm 0 18 0 22 in Installed depth b 3 0 4 0 mm 0 12 0 16 in Installed depth c 1 0 mm 0 04 in Installed depth d 0 5 mm 0 02 in Insta...

Page 252: ...d relay arm bracket locknut 5 Install Rear shock absorber assembly TIP When installing the rear shock absorber assem bly lift up the swingarm 6 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower bolt T R Connecting arm and relay arm nut 70 Nm 7 0 m kgf 50 ft lbf Connecting arm and swingarm nut 48 Nm 4 8 m kgf 35 ft lbf T R Connecting arm and relay arm locknut 56 Nm 5...

Page 253: ... 1 3 Pivot bolt locknut 1 4 Right pivot bolt 1 5 Left pivot bolt 1 6 Swingarm 1 7 Spacer 2 8 Oil seal 2 9 Bearing 2 10 Plate 2 For installation reverse the removal proce dure 6 1 8 8 7 7 9 9 10 3 4 5 5 5 10 2 New New LT LT LS LT LT LS LT 100 Nm 10 0 m kgf 72 ft lbf T R 100 Nm 10 0 m kgf 72 ft lbf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 115 Nm 11 5 m kgf 85 ft lbf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0...

Page 254: ...1 Check Swingarm Bends cracks damage Replace 2 Check Left pivot bolt Right pivot bolt Bends cracks damage Replace 3 Wash Left pivot bolt Right pivot bolt Spacers Bearings Plates 4 Check Plates Spacers Oil seals Damage wear Replace Bearings Damage pitting Replace EAS23390 INSTALLING THE SWINGARM 1 Lubricate Bearings Oil seals Spacers 2 Install Swingarm a Temporarily install the left pivot bolt and ...

Page 255: ...SWINGARM 4 90 d Tighten the pivot bolt locknut T R Pivot bolt locknut 100 Nm 10 0 m kgf 72 ft lbf ...

Page 256: ...ING THE FINAL GEAR OIL on page 3 26 Rear wheel Refer to REAR WHEEL on page 4 20 1 Swingarm inner panel 1 2 Final drive assembly 1 For installation reverse the removal proce dure 4 2 1 New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 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 42 Nm 4 2 m kgf 30 ft Ibf T R ...

Page 257: ...e 4 100 10 Baffle plate 1 11 Oil seal 1 12 Bearing 1 13 Ring gear shim Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 97 and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 100 7 10 11 13 12 8 3 6 6 14 2 2 3 3 5 4 26 4 27 16 9 24 15 21 25 23 22 19 20 18 17 3 3 2 2 1 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft...

Page 258: ...AR AND RING GEAR on page 4 100 24 Dowel pin 1 25 Bearing 1 26 Final drive case stud bolt 4 Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks 7 10 11 13 12 8 3 6 6 14 2 2 3 3 5 4 26 4 27 16 9 24 15 21 25 23 22 19 20 18 17 3 3 2 2 1 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R LT 19 Nm 1 9 m kgf...

Page 259: ...arks 7 10 11 13 12 8 3 6 6 14 2 2 3 3 5 4 26 4 27 16 9 24 15 21 25 23 22 19 20 18 17 3 3 2 2 1 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R LT 19 Nm 1 9 m kgf 13 ft Ibf T R 85 Nm 8 5 m kgf 61 ft Ibf T R 130 Nm 13 0 m kgf 94 ft lbf T R New New New New New New New New LS LS LS LS LS LS LT LT LT LT LT LS LS LS LS New G LS ...

Page 260: ...n Broken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider Troubleshooting chart When causes a or b shown in the table at the beginning of the TROUBLESHOOTING section exist check the following points YES NO Symptom Possible cause 1 A pro...

Page 261: ...vehicle may result from the applica tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to originate from EAS23581 MEASURING THE FINAL GEAR BACKLASH TIP Before measuring the final gear backlash re move the baffle plate from the final drive case 1 Secure the final drive assembly in a vise 2 Remove Final gear oil dra...

Page 262: ...ement to engagement e Record the reading on the dial gauge f Remove the dial gauge and ring gear fix bolt g Rotate the final drive pinion gear 90 h Reinstall the ring gear fix bolt and dial gauge i Repeat steps d to h three more times for a total of four measurements j If any of the readings are over specification adjust the final gear backlash EAS23591 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove R...

Page 263: ...a press c With a pipe 2 of the proper diameter posi tioned beneath the universal joint yoke 3 as shown press out the bearing 4 TIP It may be necessary to lightly tap the universal joint yoke d Repeat the above steps to remove the oppo site side s bearing e Separate the universal joint yokes 2 Remove Ring gear bearing housing bolts M12 1 Final drive case bolts M8 2 TIP Working in a crisscross patte...

Page 264: ... final drive case to approximately 150 C 302 F b Remove the bearing with an appropriately shaped punch c Remove the inner race from the final drive pinion gear TIP The removal of the final drive pinion gear bear ing is a difficult procedure and is rarely neces sary 3 Install Bearing Dowel pin a Heat the final drive case to approximately 150 C 302 F b Install the bearing with a socket or appropri a...

Page 265: ... s and the ring gear with shim s Calculate the respective thicknesses from information marked on the final drive case ring gear bearing housing and ring gear b To find final drive pinion gear shim thickness A use the following formula Where a 92 b a numeral on the final drive case to be di vided by 100 and added to 91 Example If the final drive case is marked 52 Therefore the calculated final driv...

Page 266: ...erefore the calculated ring gear shim thickness is 0 62 mm Shim sizes are supplied in the following thick nesses Since the ring gear shims are only available in 0 10 mm increments round off the hun dredths digit In the example above the calculated ring gear shim thickness is 0 62 mm The chart in structs you to round off the 2 to 0 Thus you should use a 0 60 mm ring gear shim 2 Install Shims as cal...

Page 267: ...AR BACKLASH on page 4 97 8 Measure Ring gear to thrust washer clearance a Remove the ring gear bearing housing along with the ring gear b Place four pieces of Plastigauge between the original thrust washer and the ring gear c Install the ring gear bearing housing and tighten the bolts to specification TIP Do not turn the final drive pinion gear and ring gear while measuring the ring gear to thrust...

Page 268: ... joint 2 Install Universal joint final drive side a Fit the universal joint into the yoke b Apply lithium soap based grease to the bear ings c Install the bearing 1 into the yoke NOTICE ECA2S31033 Check each bearing The needle bearings can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place d Press...

Page 269: ...al drive assembly nut 6 Install Swingarm inner panel TIP Fit the projection on the front of the swingarm inner panel into the swingarm and then install the panel Make sure that the projections a on the swin garm inner panel are securely fitted into the swingarm 7 Install Rear wheel Refer to REAR WHEEL on page 4 20 8 Fill Final gear case Refer to CHECKING THE ENGINE OIL LEVEL on page 3 10 T R Final...

Page 270: ...SHAFT DRIVE 4 105 ...

Page 271: ...MOVING 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 34 CHECKING THE VALVE LIFTERS 5 34 INSTALLING THE VALVES 5 34 GENERATOR AND STARTER CLUTCH 5 37 REMOVING THE GENERATOR 5 40 REMOVING THE STARTER ...

Page 272: ...YLINDER 5 63 SHIFT SHAFT 5 65 CHECKING THE SHIFT SHAFT 5 67 CHECKING THE STOPPER LEVER 5 67 INSTALLING THE SHIFT SHAFT 5 67 OIL PUMP 5 68 REMOVING THE OIL PAN 5 71 CHECKING THE OIL PUMP 5 71 CHECKING THE RELIEF VALVE 5 71 CHECKING THE OIL PIPE 2 5 72 CHECKING THE OIL STRAINER 5 72 ASSEMBLING THE OIL PUMP 5 72 INSTALLING THE OIL PUMP 5 72 INSTALLING THE OIL PAN 5 72 CRANKCASE 5 73 DISASSEMBLING THE...

Page 273: ...IDDLE GEAR 5 105 REMOVING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 5 109 DISASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 5 109 REMOVING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 5 109 DISASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 5 109 CHECKING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 5 110 CHECKING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 5 110 ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 5 1...

Page 274: ... EXUP cable 1 1 Black adjusting bolt 10 EXUP cable 2 1 11 O2 sensor coupler 1 Disconnect 12 O2 sensor 1 13 Exhaust chamber 1 14 Gasket 2 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 8 Nm 0 8 m kgf 5 8 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 45 Nm 4 5 m kgf 32 ft Ibf T R 7 Nm 0 7 m kgf 5 1 f...

Page 275: ...t chamber and exhaust pipes Order Job Parts 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 8 Nm 0 8 m kgf 5 8 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 45 Nm 4 5 m kgf 32 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 276: ...n page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 11 Air induction system hoses Refer to AIR INDUCTION SYSTEM on page 7 19 Thermostat inlet pipes Refer to THERMOSTAT on page 6 7 Radiator assembly Refer to RADIATORS on page 6 1 Water pump outlet pipe Water pump inlet pipe Refer to WATER PUMP on page 6 11 Oil cooler adapter Refer to OIL COOLER on page 6 5 1 Ignition coil coupler 4 Discon...

Page 277: ...ler 1 Disconnect 7 Sidestand 1 8 Oil level switch coupler 1 Disconnect 9 Gear position switch coupler 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hose Order Job Parts to remove Q ty Remarks 8 6 7 4 1 1 2 1 1 5 9 3 LT LT LT 28 Nm 2 8 m kgf 20 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 278: ...e bracket bolt front left side 1 12 Engine bracket bolt front center side 1 13 Engine bracket front side 1 14 Engine mounting bolt rear right upper side 1 15 Engine mounting collar outside 1 LS 18 20 21 14 15 16 27 26 23 2 2 3 1 17 24 4 10 Nm 1 0 m kgf 7 2 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 8 Nm 0 8 m kgf 5 8 ft Ibf T R 20 Nm 2 0 m ...

Page 279: ...Cylinder head breather pipe lower side 1 For installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks LS 18 20 21 14 15 16 27 26 23 2 2 3 1 17 24 4 10 Nm 1 0 m kgf 7 2 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 8 Nm 0 8 m kgf 5 8 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf...

Page 280: ...de 7 Engine mounting bolt rear left upper side 8 Engine mounting bolt rear right upper side 9 3 Install Engine bracket left side 16 Engine mounting bolts left side 17 Engine bracket bolts left side 18 Engine bracket right side 19 Engine mounting bolts right side 20 Engine bracket bolts right side 21 TIP Do not fully tighten the bolts 4 Tighten Engine mounting bolts left side 17 Engine bracket bolt...

Page 281: ...osed position as shown 2 Install EXUP cable 1 1 EXUP cable 2 2 a Install the EXUP cable 1 1 onto the servo motor pulley and then install the cable onto the right side of the EXUP bracket TIP The correct installation position for the EXUP cable 1 is identified by the casting mark a on the EXUP servo motor EXUP cable 1 is identified by a black adjusting bolt b 3 Adjust EXUP cables Refer to ADJUSTING...

Page 282: ...DUCTION SYSTEM on page 7 19 1 Ignition coil coupler 4 Disconnect 2 Ignition coil 4 3 Spark plug 4 4 Cylinder head breather hose 1 5 Cylinder head breather pipe upper side 1 6 Cylinder identification sensor 1 7 Cylinder head side cover 8 8 Cylinder head side cover plate 8 9 Rear cylinder head cover 1 1 4 3 2 4 4 9 7 7 8 8 7 7 8 8 8 7 7 8 10 11 11 8 7 1 1 7 6 3 2 3 2 8 5 LS New New New New LT LT LT ...

Page 283: ...e Q ty Remarks 1 4 3 2 4 4 9 7 7 8 8 7 7 8 8 8 7 7 8 10 11 11 8 7 1 1 7 6 3 2 3 2 8 5 LS New New New New LT LT LT LS LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT 5 Nm 0 5 m kgf 3 6 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 12 Nm 1 2 m kgf 8 7 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 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 284: ...ward 4 Timing chain tensioner gasket rear cylinders 1 5 Rear cylinder timing chain guide intake side 1 6 Intake camshaft cap rear cylinders 2 7 Intake camshaft rear cylinders 1 8 Intake camshaft sprocket rear cylinders 1 9 Intake camshaft gear rear cylinders 1 10 Exhaust camshaft cap front cylinders 2 11 Exhaust camshaft front cylinders 1 9 17 18 10 3 16 5 6 1 16 8 11 2 14 19 15 12 13 4 16 7 M M 1...

Page 285: ...take camshaft gear front cylinders 1 19 Timing chain guide stopper 1 For installation reverse the removal proce dure Removing the camshafts Order Job Parts to remove Q ty Remarks 9 17 18 10 3 16 5 6 1 16 8 11 2 14 19 15 12 13 4 16 7 M M 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 24 Nm 2 ...

Page 286: ... sure to identify the cylinder of each camshaft cap so that it can be reinstalled in its original place 3 Remove Exhaust camshaft rear cylinders 4 Remove Timing chain tensioner rear cylinders Timing chain tensioner gasket rear cylin ders 5 Remove Rear cylinder timing chain guide intake side 6 Remove Intake camshaft caps rear cylinders NOTICE ECA13720 To prevent damage to the cylinder head camshaft...

Page 287: ...e found when the I mark c in the intake camshaft gear front cylinders is aligned with the edge of the cylinder head d EAS23850 CHECKING THE CAMSHAFTS The following procedure applies to all of the camshafts 1 Check Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft Rotor holding tool 90890 01...

Page 288: ...aft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set EAS23870 CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the camshaft sprockets 1 Check Camshaft spr...

Page 289: ...ve the timing chain tensioner spring and timing chain tensioner rod 2 Check Timing chain tensioner housing Timing chain tensioner rod Timing chain tensioner spring seat Timing chain tensioner spring Timing chain tensioner clips Damage wear Replace the timing chain tensioner 3 Assemble Timing chain tensioner TIP Prior to installing the timing chain tensioner rod drain the engine oil from the timing...

Page 290: ...and then squeeze the clip to fit it into the groove TIP Make sure that the timing chain tensioner rod is secured by the clip otherwise the rod may be ejected EAS24020 INSTALLING THE CAMSHAFTS Front cylinders intake side 1 Install Intake camshaft gear 1 TIP Install the camshaft gear onto the left side of the camshaft Install the camshaft gear so that the bolt hole next to the F mark a is aligned wi...

Page 291: ...er 4 Install Intake camshaft 1 with the camshaft gear and camshaft sprocket Timing chain Intake camshaft caps 2 NOTICE ECA2S31034 Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing TIP Be sure to install the timing chain so that the exhaust side of the chain is taut and the intake side is slack Make sure each camshaft cap is installed in its original p...

Page 292: ... a few times to release the timing chain tensioner rod TIP If the timing chain tensioner rod does not re lease rotate the crankshaft clockwise 9 Check that the timing chain is taut If the chain is slack reinstall the timing chain ten sioner Front cylinders exhaust side 1 Find Front cylinders exhaust camshaft installation position a Make sure that the F mark on the generator rotor is aligned with t...

Page 293: ...Refer to the identification marks as follows Exhaust left side 2S3 78 Exhaust right side 2S3 83 3 Install Exhaust camshaft cap bolts NOTICE ECA2S31035 The camshaft cap bolts must be tightened evenly otherwise the cylinder head cam shaft caps and camshaft will be damaged TIP Lubricate the camshaft cap bolt mating surface with molybdenum disulfide oil Tighten the camshaft cap bolts in stages and in ...

Page 294: ...ing tool 2 tighten the camshaft sprocket bolts 3 Find Rear cylinders intake camshaft installation position a Make sure that piston 2 is at TDC b Turn the crankshaft about a turn and 1 4 462 degrees counterclockwise until the R mark a on the generator rotor is aligned with the stationary pointer b on the generator cover 4 Install Intake camshaft 1 with the camshaft gear and camshaft sprocket Timing...

Page 295: ...ps and camshaft will be damaged TIP Lubricate the camshaft cap bolt mating surface with molybdenum disulfide oil Tighten the camshaft cap bolts in stages and in a crisscross pattern 6 Install Timing chain guide 7 Install Timing chain tensioner gasket 1 Timing chain tensioner 2 TIP Be sure to install the timing chain tensioner gasket so that its projection a is protruding from the upper left side o...

Page 296: ... with punch mark b in the exhaust camshaft gear Insert a cross headed screwdriver 3 into one of the holes of the exhaust camshaft gear and then rotate the outer exhaust camshaft gear until both exhaust camshaft gears are aligned The teeth of both exhaust camshaft gears must be aligned for installation Make sure each camshaft cap is installed in its original place Refer to the identification marks ...

Page 297: ...mark on the intake camshaft gear rear cyl inders above the edge of the cylinder head TIP Check that the I mark a on the intake cam shaft gear front cylinders is aligned with the edge of the cylinder head b Check that the I mark c on the intake cam shaft gear rear cylinders is above the edge of the cylinder head d Out of alignment Adjust Refer to the installation steps above 7 Measure Valve clearan...

Page 298: ...ll Ignition coils 1 TIP When installing the ignition coils make sure that the ignition coil couplers are positioned at the angles shown in the illustration A Front cylinders B Rear cylinders 1 30 30 A FWD 1 1 B 90 90 FWD 1 1 ...

Page 299: ...mperature sensor 1 2 Front cylinder head 1 3 Rear cylinder head 1 4 Cylinder head gasket 2 5 Dowel pin 4 For installation reverse the removal proce dure 1 8 8 4 3 5 5 5 5 4 2 New New New New New New New New New 1st 30 Nm 3 0 m kgf 22 ft lbf Final Specified angle 85 95 T R 1st 30 Nm 3 0 m kgf 22 ft lbf Final Specified angle 85 95 T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 18 Nm...

Page 300: ...nder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 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 a 400 600 grit wet sandpaper on the surface plate and r...

Page 301: ...in the prop er tightening sequence as shown WARNING EWA2S31035 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA2S31041 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle TIP On a hexagonal bolt...

Page 302: ...CYLINDER HEADS on page 5 26 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Intake valve guide 4 Length 35 mm 1 38 in 11 Exhaust valve guide 4 Length 39 mm 1 54 in For installation reverse the removal proce dure 8 4 3 3 5 9 New New 11 7 New 10 6 New M M E E E M M M M M E M 9 ...

Page 303: ...ur a cleaning solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring se...

Page 304: ...ter installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b 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...

Page 305: ...cedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide install...

Page 306: ...enum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f Aft...

Page 307: ...e lifter Damage scratches Replace the valve lift ers and cylinder head EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone Free length intake 40 78 mm 1 61 in Limit 38 74 mm 1 53 in Free length exhaust 40 78 mm 1 61 in Limit 38 74 mm 1 53 in Installed compression spring force intake 186 00 214 00 N 18 ...

Page 308: ...led in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil New b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Val...

Page 309: ...force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil ...

Page 310: ...release cylinder cover 1 2 Generator cover plate 1 3 Generator cover plate damper 1 4 Oil pipe 1 1 5 Crankshaft position sensor stator assembly lead holder 2 1 6 Generator cover 1 7 Generator cover gasket 1 8 Dowel pin 2 9 Oil nozzle 1 LT LT New LT New New New New 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 10 Nm 1 0 m...

Page 311: ...moving the stator coil Order Job Parts to remove Q ty Remarks LT LT New LT New New New New 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R LS LS LS 8 8 3 1 12 11 12 6 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R LS LT LT LT LT 4 2 9 6 5 10 7 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 312: ...tor 1 2 Washer 1 3 Starter clutch 1 4 Woodruff key 1 5 Starter clutch gear 1 6 Starter idle gear shaft 1 7 Starter idle gear 1 8 Starter clutch idle gear shaft 1 9 Starter clutch idle gear 1 For installation reverse the removal proce dure LT 32 Nm 3 2 m kgf 23 ft Ibf T R E E E E E E 1 6 2 3 8 6 7 9 5 4 80 Nm 8 0 m kgf 58 ft Ibf T R New ...

Page 313: ...he threaded holes of the starter clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 remove the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS24570 CHECKING THE STARTER CLUTCH...

Page 314: ...the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS24500 INSTALLING THE GENERATOR 1 Install Woodruff key 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 sealed in the key...

Page 315: ...or cover gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern 6 Install Generator cover plate damper Generator cover plate 1 TIP Install the generator cover plate so that the let tering in the recycle mark a is right side up Tighten the generator cover plate bolts in stag es and in a crisscross pattern Sheave holder 90890 01701 Primary clutch holder YS...

Page 316: ...GENERATOR AND STARTER CLUTCH 5 43 a 1 ...

Page 317: ... Order Job Parts to remove Q ty Remarks Front exhaust pipes Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure 1 2 LS New 20 Nm 2 0 m kgf 14 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 318: ...over 1 4 Bearing 1 5 Oil seal 1 6 Circlip 1 7 Starter motor rear cover 1 8 Brush seat along with brushes 1 9 Brush spring 4 10 Brush 2 11 Bearing 1 12 O ring 2 13 Armature assembly 1 14 Starter motor yoke 1 For assembly reverse the disassembly pro cedure New 10 9 9 4 5 7 3 2 1 6 New New New New 12 11 12 8 13 14 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 319: ... of specification Replace the starter motor a Measure the armature assembly resistance with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica undercut depth 1 00 mm ...

Page 320: ...ection a on the starter motor rear cover with the slot b in the brush seat 2 Install Starter motor yoke 1 Starter motor rear cover 2 TIP Align the projection a on the starter motor rear cover with the slot b in the starter motor yoke 3 Install Starter motor yoke 1 Starter motor front cover 2 TIP Align the match marks a on the starter motor yoke with the match mark b on the starter mo tor front cov...

Page 321: ...ne oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Clutch cover damper plate 1 5 Clutch cover damper 1 For installation reverse the removal proce dure New 2 1 5 4 5 5 3 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 322: ...essure plate 1 5 Short clutch push rod 1 6 Ball 1 7 Long clutch push rod 1 8 Friction plate 10 9 Clutch plate 1 1 10 Clutch plate 2 1 11 Clutch plate 3 7 12 Clutch boss nut 1 13 Spring 4 14 Clutch boss 1 15 Clutch boss plate 1 16 Conical spring washer 1 New LS E E E E E E LT 24 19 20 21 22 23 23 18 17 16 15 14 6 13 12 New 8 9 10 11 7 LS 6 5 New 1 6 2 3 4 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m k...

Page 323: ...pin 3 24 Thrust washer 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks New LS E E E E E E LT 24 19 20 21 22 23 23 18 17 16 15 14 6 13 12 New 8 9 10 11 7 LS 6 5 New 1 6 2 3 4 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m kgf 68 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R ...

Page 324: ...r reservoir cap 1 3 Clutch master cylinder reservoir diaphragm holder 1 4 Clutch master cylinder reservoir diaphragm 1 5 Clutch lever 1 6 Bushing 1 7 Clutch switch coupler 1 Disconnect 8 Clutch switch 1 9 Clutch hose union bolt 1 10 Clutch hose gasket 2 11 Clutch hose 1 Disconnect 12 Clutch master cylinder holder 1 30 Nm 3 0 m kgf 22 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R S S 10 9 11 8 6 7 12 1 ...

Page 325: ...cylinder 1 For installation reverse the removal proce dure Removing the clutch master cylinder Order Job Parts to remove Q ty Remarks 30 Nm 3 0 m kgf 22 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R S S 10 9 11 8 6 7 12 1 5 13 2 3 4 New ...

Page 326: ...g the clutch master cylinder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Clutch master cylinder kit 1 3 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure 3 2 1 New S ...

Page 327: ...er to GENERATOR AND STARTER CLUTCH on page 5 37 1 Clutch hose union bolt 1 2 Clutch hose gasket 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Clutch release cylinder plate 1 7 Oil seal 1 For installation reverse the removal proce dure LS LT New LT 5 5 7 3 1 2 4 6 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 328: ... Parts to remove Q ty Remarks 1 Boot 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 For assembly reverse the disassembling procedure S 5 3 4 2 1 New New S 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 329: ...tch re lease cylinder side of the engine and remove it from the clutch side of the engine 4 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 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 F...

Page 330: ...nd clutch plates were replaced To measure the total width of the friction plates and clutch plates combine 9 friction plates and 9 clutch plates as shown a Adjust the total width by replacing the clutch plate 1 and if necessary clutch plate 2 b Select the clutch plate from the following ta ble TIP When adjusting the clutch assembly width by replacing the clutch plate s be sure to replace the clutc...

Page 331: ...ace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace Bearing Damage wear Replace EAS25190 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limi...

Page 332: ... plates with the recommended lubricant 4 Install Friction plates Clutch plates TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align a projection on the friction plate with the punch mark a on the clutch housing 5 Install Clutch spring plate 1 Clutch spring pla...

Page 333: ...d and bled after reas sembly Never use solvents on internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with w...

Page 334: ...YLINDER 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 TIP Align the end of the clutch master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 2 Install Clutch hose gasket 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EWA13360 Proper clutch hose routing is essential to in sure safe motorcycle operation Refer to CABLE RO...

Page 335: ...r to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal 4 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 13 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 13 6 Check Clutch lever operation Soft or spongy fee...

Page 336: ...h hose union bolt 3 NOTICE ECA2S31042 When installing the clutch hose onto the clutch release cylinder make sure the pipe a touches the projection b on the clutch release cylinder body 3 Fill Clutch master cylinder reservoir with the specified amount of the recom mended clutch fluid WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate ...

Page 337: ...eck Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 13 6 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 13 a ...

Page 338: ... The shift rod locknut shift pedal side has left hand threads 2 Shift arm 1 3 Circlip 1 4 Washer 1 5 Shift shaft 1 6 Washer 1 7 Spacer 1 8 Shift shaft spring 1 9 Stopper lever spring 1 10 Stopper lever 1 11 Shift shaft spring stopper 1 12 Oil seal 1 1 LS New New E 2 3 4 12 13 5 10 9 7 8 6 13 11 LT LT E E 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 22...

Page 339: ... proce dure Removing the shift arm and shift shaft Order Job Parts to remove Q ty Remarks 1 LS New New E 2 3 4 12 13 5 10 9 7 8 6 13 11 LT LT E E 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 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 340: ...ankcase 2 Install Stopper lever 1 Stopper lever spring 2 TIP Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 3 Install Shift shaft 1 TIP Hook the end of the shift shaft spring onto the shift shaft spring stopper 2 4 Install Shift arm 1 TIP Align the punch mark a in the shift shaft with the slot i...

Page 341: ...h housing Refer to CLUTCH on page 5 48 1 Oil level switch coupler 1 Disconnect 2 Oil level switch lead holder 1 3 Oil level switch 1 4 Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 7 Oil pipe 2 1 8 Oil strainer 1 9 Oil pump 1 LS LT 10 10 FWD 4 6 2 1 3 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 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 342: ...l pump assembly Order Job Parts to remove Q ty Remarks LS LT 10 10 FWD 4 6 2 1 3 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R New New LS New New New 8 7 5 9 10 8 9 7 6 LT LT LT E ...

Page 343: ...rder Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Oil pump inner rotor 1 3 Oil pump outer rotor 1 4 Pin 1 5 Washer 1 6 Oil pump driven gear 1 7 Oil pump housing 1 For assembly reverse the disassembly pro cedure 2 4 1 5 6 7 3 LS ...

Page 344: ...b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to ou...

Page 345: ...e inner rotor align the pin 3 in the oil pump shaft with the groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 71 EAS25030 INSTALLING THE OIL PUMP 1 Install Oil pump 1 TIP Align the arrow mark a on the oil pump with the arrow mark b on the crankcase EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Apply locking agent LOCTITE to t...

Page 346: ...r cover 1 4 Ventilation chamber cover gasket 1 5 Main axle bearing retainer 1 6 Middle gear side cover 1 7 Middle gear side cover gasket 1 8 Dowel pin 2 New LS E E E E E E E New New New LT LT LT LT LT LT LT E E 7 4 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 5 Nm 0 5 m kgf 3 6 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 347: ...S E E E E E E E New New New LT LT LT LT LT LT LT E E 7 4 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 5 Nm 0 5 m kgf 3 6 ft Ibf T R 12 Nm 1 2 m kgf 8 7 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 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 1st 30 Nm 3 0 m kgf 22 ft lbf 2nd 25 N...

Page 348: ...2 Transmission Refer to TRANSMISSION on page 5 98 1 Plate 1 2 Oil pipe 3 1 3 Damper 1 4 Oil nozzle 3 M6 5 Oil nozzle 2 M8 For installation reverse the removal proce dure 2 4 1 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 6 Nm 0 6 m kgf 4 3 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 20 Nm 2 0 m kgf 14 ft Ibf T R New LS New...

Page 349: ...se NOTICE ECA13900 Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfac...

Page 350: ...ating surfaces NOTICE ECA2S31066 Do not allow any sealant to come into con tact with the oil gallery crankshaft journal bearings or balancer shaft journal bearings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bearings 3 Install Dowel pins 4 Set the shift drum assembly and transmission gears in the neutral position 5 Install Lower crankcase 1 onto the upper crankcase...

Page 351: ...he tightening procedure of crankcase bolts 1 8 is angle controlled therefore tighten the bolts using the following procedure a Tighten the crankcase bolts in the proper tightening sequence as shown b Loosen and retighten the crankcase bolt 1 c Tighten the crankcase bolt 1 further to reach the specified angle 80 New 1 1 1 1 30 29 1 2 3 4 5 6 7 8 10 9 11 13 12 14 15 16 17 18 19 21 20 22 23 24 25 26 ...

Page 352: ... Tighten the bolt until it is at the specified angle TIP On a hexagonal bolt note that the angle from one corner to another is 60 d Repeat steps a and b for each of the crankcase bolts 2 8 in order 8 Tighten Crankcase bolts 9 42 TIP Tighten the crankcase bolts in the proper tight ening sequence as shown 1 2 3 4 5 6 7 8 T R Crankcase bolt 9 27 31 39 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt 28 30 40...

Page 353: ...up 10 Install Main axle bearing retainer 1 TIP Install the main axle bearing retainer with its OUT mark a facing outward A Lower crankcase B Upper crankcase T R Middle drive pinion gear bearing retainer bolt 24 Nm 2 4 m kgf 17 ft lbf LOCTITE T R Main axle bearing retainer bolt 12 Nm 1 2 m kgf 8 7 ft lbf LOCTITE 42 39 41 37 34 33 32 31 35 40 36 38 B 1 a 1 a ...

Page 354: ...onnecting rod cap 4 3 Big end lower bearing 4 4 Big end upper bearing 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Connecting rod 4 9 Top ring 4 10 2nd ring 4 11 Oil ring 4 For installation reverse the removal proce dure M M 8 5 4 3 2 1 1 1 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 1st 20 Nm 2 0 m kgf 14 ft lbf 2nd Specified angle 130 140 T...

Page 355: ...ing installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other s...

Page 356: ...clearance with the following formula f If out of specification replace the upper crankcase piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification 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 Bore 90 00...

Page 357: ...n check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Piston ring Top ring Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in a 9 8 mm 0 39 in...

Page 358: ...g 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 bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves TIP Lubricate the bolt threads and seats with mo lybdenum disulfide oil Make sure that the...

Page 359: ...en the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Make sure the Y mark a on the 1 and 3 connecting rods faces toward the left side of the crankcase Make sure the Y mark a on the...

Page 360: ... the bolts until they are within the specified angles TIP After installation check that the section a is flush by running your finger across the surface m Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 82 n Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specifica...

Page 361: ...rrying out the following procedures in order to assemble in the most suitable condition a Replace the connecting rod bolts with new ones b Clean the connecting rod bolts c After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them onto the crankshaft d Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with...

Page 362: ...m the cutout in the piston as shown in the illustration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 5 Lubricate Piston Piston rings Cylinder with the recommended lubricant 6 Offset Piston ring end gaps 7 Lubricate Connecting rod bolt threads with the recommended lubricant 8 Lubricate Crankshaft pins Big end bearings Connecting rod big end inner su...

Page 363: ...r to reach the specified angle WARNING EWA2S31014 When a bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to replace the connecting ...

Page 364: ...CONNECTING RODS AND PISTONS 5 91 a ...

Page 365: ...n page 5 73 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 81 1 Balancer shaft 1 2 Balancer shaft journal upper bearing 4 3 Balancer shaft journal lower bearing 4 4 Crankshaft 1 5 Timing chain 2 6 Crankshaft journal upper bearing 4 7 Crankshaft journal lower bearing 4 For installation reverse the removal proce dure E E E E E E E E E FWD 3 6 7 7 4 7 5 2 2 1 ...

Page 366: ...ion Replace the crank shaft 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches wear Replace the crankshaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft jour...

Page 367: ...g Remove the lower crankcase and the crank shaft journal lower bearings h Measure the compressed Plastigauge width g on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J4 TIP The numbers A stamped into the lower crank case and the numbers B stam...

Page 368: ...ncer shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 2 on each bal ancer shaft journal TIP Do not...

Page 369: ...rs B stamped into the balancer shaft web are used to determine the replacement balancer shaft journal bearing siz es J1 J4 refer to the bearings shown in the lower crankcase and balancer shaft web illustration If J1 J4 are the same use the same size for all of the bearings For example if the lower crankcase J1 and balancer shaft web J1 numbers are 8 and 5 respectively then the bearing size for J1 ...

Page 370: ...ing into the crankcase secure it with a wire EAS26220 INSTALLING THE BALANCER SHAFT 1 Install Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each balancer shaft journal bearing in its original plac...

Page 371: ... on page 5 73 1 Drive axle middle drive pinion gear assembly 1 2 Main axle assembly 1 3 Shift drum retainer 2 4 Long shift fork guide bar 1 5 Shift fork C 1 6 Short shift fork guide bar 1 7 Shift fork R 1 8 Shift fork L 1 9 Shift drum assembly 1 10 Bearing 1 For installation reverse the removal proce dure LT E E LT 3 6 9 1 2 3 4 FWD E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 7 8 E 5 ...

Page 372: ...sher 1 5 Toothed lock washer retainer 1 6 5th pinion gear 1 7 Toothed spacer 1 8 Toothed washer 1 9 Circlip 1 10 3rd pinion gear 1 11 Circlip 1 12 Toothed washer 1 13 4th pinion gear 1 14 Collar 1 15 Bearing 1 16 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure 2 4 5 1 11 3 7 12 6 9 10 15 16 14 13 8 E New New New E M M M M M M M ...

Page 373: ... GEAR on page 5 105 1 Bearing 1 2 Washer 1 3 1st wheel gear 1 4 Collar 1 5 4th wheel gear 1 6 Circlip 1 7 Toothed washer 1 8 3rd wheel gear 1 9 Toothed spacer 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 12 5th wheel gear 1 13 Circlip 1 14 Toothed washer 1 15 2nd wheel gear 1 16 Collar 1 2 4 5 1 3 6 7 8 17 10 9 11 12 13 14 15 16 E New New M M M M M M M M ...

Page 374: ...ve axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle middle drive pinion gear assembly Order Job Parts to remove Q ty Remarks 2 4 5 1 3 6 7 8 17 10 9 11 12 13 14 15 16 E New New M M M M M M M M ...

Page 375: ...place the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 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 centering device a...

Page 376: ...AXLE AND DRIVE AXLE 1 Install Circlip 1 TIP Install the circlip so that a spline a is in the cen ter of the gap between the circlip ends b as shown 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer 2 Be sure to align ...

Page 377: ...n the shift forks should face towards the right side of the engine and be in the following sequence R C L 2 Install Shift drum retainer 1 TIP Install the shift drum retainer with its OUT mark a facing outward 3 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly A Main axle B Drive axle T R Shift drum retainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE A 2 1 1 2 B ...

Page 378: ...dle driven pinion gear shim Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 113 and ALIGNING THE MIDDLE GEAR on page 5 114 6 Universal joint yoke nut middle gear side 1 7 Washer 1 8 Universal joint yoke middle gear side 1 9 Middle driven pinion gear 1 10 Expander 1 11 Washer 1 12 Bearing 1 13 Oil seal 1 14 Bearing 1 LS LS LS LS 5 3 5 9 7 8 6 1 4 2 2 2 12 15 11 10 16 14 13 15 New New New New ...

Page 379: ...using 1 For installation reverse the removal proce dure Removing the middle driven pinion gear Order Job Parts to remove Q ty Remarks LS LS LS LS 5 3 5 9 7 8 6 1 4 2 2 2 12 15 11 10 16 14 13 15 New New New New LS LS LT 30 Nm 3 0 m kgf 22 ft Ibf T R LS LT 2 1 1 1 FWD 4 E E LS E ...

Page 380: ... Refer to ALIGNING THE MIDDLE GEAR on page 5 114 3 Drive axle middle drive pinion gear assembly 1 4 Spring retainer 2 5 Washer 1 6 Middle drive pinion gear assembly 1 7 Torque damper cam 1 8 Spring 1 9 Spring seat 1 10 Bearing 1 11 Middle drive pinion gear nut 1 12 Middle drive pinion gear 1 13 Bearing 1 4 2 8 2 4 5 1 11 13 14 3 7 12 6 9 10 M E New E E LT M 24 Nm 2 4 m kgf 17 ft Ibf T R 110 Nm 11 ...

Page 381: ... housing 1 For installation reverse the removal proce dure Removing the middle drive pinion gear Order Job Parts to remove Q ty Remarks 4 2 8 2 4 5 1 11 13 14 3 7 12 6 9 10 M E New E E LT M 24 Nm 2 4 m kgf 17 ft Ibf T R 110 Nm 11 0 m kgf 80 ft lbf T R FWD ...

Page 382: ...TIP Straighten the collar on the universal joint yoke nut Wrap the middle driven pinion gear bearing housing in a folded rag and then secure it in a vise While holding the universal joint yoke 2 with the universal joint holder 3 loosen the univer sal joint yoke nut EAS2S31049 REMOVING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1 Remove Spring retainers 1 Washer TIP While compressing the spring with the...

Page 383: ...hes wear Replace 3 Check Spring Cracks damage Replace 4 Check Bearing Damage pitting Replace EAS2S31053 ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1 Install Middle drive pinion gear nut a Attach the middle drive shaft nut wrench 55 mm 1 TIP Wrap the middle drive pinion gear in a folded rag and then secure it in a vise b Tighten the middle drive pinion gear nut to specification c Lock the thr...

Page 384: ... driven pinion gear bearing housing in a folded rag and then secure it in a vise While holding the universal joint yoke 2 with the universal joint holder 3 tighten the univer sal joint yoke nut After tightening the nut check the operation of the middle driven pinion gear assembly If there is looseness in the assembly disassem ble it and check if the bearings are installed properly When reassemblin...

Page 385: ...pecification Adjust the backlash EAS2S31056 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1 Install Universal joint middle gear side a Fit the universal joint into the yoke b Apply lithium soap based grease to the bear ings c Install the bearing 1 into the yoke NOTICE ECA2S31033 Check each bearing The needle bearings can easily fall out of their races Slide the yoke back and forth on the beari...

Page 386: ... measure the middle gear backlash TIP Measure the middle gear backlash at four posi tions Rotate the universal joint yoke 90 each time and observe the reading on the dial gauge EAS25900 ADJUSTING THE MIDDLE GEAR BACKLASH 1 Loosen Middle driven pinion gear bearing housing bolts 2 Remove Middle driven pinion gear shim s 3 Tighten Middle driven pinion gear bearing housing bolts NOTICE ECA2S31049 Do n...

Page 387: ...d thickness and select the appropriate shim with the following chart b For example the clearance between the crankcase and the middle driven pinion gear bearing housing is 0 46 mm Therefore the chart instructs you to round off the 6 to 5 Thus you should use one 0 15 mm and one 0 30 mm shim Shims are supplied in the following thickness es 8 Loosen Middle driven pinion gear bearing housing bolts 9 I...

Page 388: ... 14 50 0 07 14 57 b is 57 70 If the upper crankcase is marked 68 c is 71 68 i e 71 00 0 68 71 68 A 14 57 57 70 71 68 0 59 Round off to the hundredths digit and select the appropriate shim s TIP In the above example the calculated number is 0 59 The chart instructs you to round off the 9 to 10 Thus the shim thickness is 0 60 mm Shims are supplied in the following thickness es c To find middle drive...

Page 389: ... driven pinion gear is marked 03 e is 12 03 i e 12 00 0 03 12 03 If the middle driven pinion gear is marked 02 f is 61 98 i e 62 00 0 02 61 98 If the upper crankcase is marked 93 g is 103 93 i e 103 00 0 93 103 93 TIP If the upper crankcase is marked 00 g is 104 00 B 54 72 12 03 61 98 103 93 0 74 Round off to the hundredths digit and select the appropriate shim s TIP In the above example the calcu...

Page 390: ...MIDDLE GEAR 5 117 ...

Page 391: ... OIL COOLER 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 9 INSTALLING THE THERMOSTAT ASSEMBLY 6 9 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 INSTALLING THE WATER PUMP 6 14 ...

Page 392: ...nt reservoir breather hose 1 6 Coolant reservoir cap 1 7 Coolant reservoir cover 1 8 Coolant reservoir 1 9 Coolant reservoir hose 1 10 Upper radiator inlet hose 1 11 Upper radiator inlet pipe 1 15 10 11 12 19 18 17 2 14 9 6 5 16 7 8 4 20 13 1 3 LT LT LT LT LT LT 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 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 k...

Page 393: ...r bracket 1 For installation reverse the removal proce dure Removing the radiator assembly Order Job Parts to remove Q ty Remarks 15 10 11 12 19 18 17 2 14 9 6 5 16 7 8 4 20 13 1 3 LT LT LT LT LT LT 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 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 16 Nm 1 6 m kgf 11 ft Ibf T R 4 Nm 0 4 m kgf 2...

Page 394: ...adiator inlet hose 1 8 Lower radiator side panel 2 9 Lower radiator cover 1 10 Main radiator fan 1 11 Lower radiator 1 For assembly reverse the disassembly pro cedure 2 10 7 1 1 9 11 8 8 6 4 3 5 LT LT 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 7 Nm 0 7 m kgf 5 1 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 ...

Page 395: ...k Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS2S31080 INSTALLING THE RADIATOR ASSEMBLY 1 Install Radiator hoses Radiator pipe Refer to COOLING SYSTEM DIAGRAMS on page 2 43 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace any fault...

Page 396: ...T on page 3 19 Radiator assembly Refer to RADIATORS on page 6 1 1 Oil cooler outlet hose 1 2 Oil cooler inlet hose 1 3 Oil filter cartridge 1 4 Oil cooler union bolt 1 5 Oil cooler 1 6 Oil cooler adapter 1 For installation reverse the removal proce dure E LT LT New New 1 2 4 3 4 5 6 12 Nm 1 2 m kgf 8 7 ft Ibf T R 63 Nm 6 3 m kgf 45 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ib...

Page 397: ...il cooler union bolt with a thin coat of engine oil Make sure the O ring is positioned properly 4 Install Oil cooler hoses Refer to COOLING SYSTEM DIAGRAMS on page 2 43 5 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 11 6 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount...

Page 398: ...isconnect 4 Thermostat cover radiator filler pipe 1 5 Thermostat 1 6 Thermostat inlet hose 2 front cylinders 1 7 Thermostat inlet pipe 2 front cylinders 1 8 Thermostat inlet hose 1 front cylinders 1 9 Thermostat inlet pipe 1 front cylinders 1 10 Thermostat inlet hose rear cylinders 1 11 12 10 6 13 4 2 5 1 3 14 9 8 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R New New New LS LS LT ...

Page 399: ...val proce dure Removing the thermostat assembly Order Job Parts to remove Q ty Remarks 11 12 10 6 13 4 2 5 1 3 14 9 8 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R New New New LS LS LT New New LS 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 10 Nm 1 0 m kgf 7 2 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 ...

Page 400: ...ercooling 2 Check Thermostat housing Cracks damage Replace 3 Check Thermostat hoses Thermostat pipes Upper radiator inlet hose Thermostat cover radiator filler pipe Cracks damage wear Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat housing bracket 1 Thermostat housing 2 TIP Make sure the rib a on the thermostat housing touches the thermostat housing bracket 2 Install Therm...

Page 401: ...he recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 5 Check Cooling system Leaks Repair or replace any faulty part 6 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATORS on page 6 4 a ...

Page 402: ...h cover Refer to CLUTCH on page 5 48 1 Water pump outlet pipe 1 2 Water pump inlet pipe 1 3 Water pump cover 1 4 Crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Crankcase cover sleeve 1 8 Circlip 1 9 Washer 2 10 Circlip 1 LT LT 3 6 15 14 15 17 16 5 7 6 6 4 12 13 11 10 9 8 2 1 LS New New New New New New New New New LS LS LS E LT LT 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 10 Nm...

Page 403: ... 17 Oil seal 1 For installation reverse the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks LT LT 3 6 15 14 15 17 16 5 7 6 6 4 12 13 11 10 9 8 2 1 LS New New New New New New New New New LS LS LS E LT LT 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 404: ...ater pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS26570 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the crankcase cover 2 Install Water pump seal 1 into the crankcase cover 2 NOTICE ECA14080 Never lubricate the water pump seal surface with oil or grease TIP Apply coolant to the lip of the water pump seal Install the water pump seal with the special tools 2 1 2 3 1 I...

Page 405: ...UMP 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace the faulty part 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATORS on page 6 4 4 Middle driven shaft bearing driver A Push down New 1 ...

Page 406: ...WATER PUMP 6 15 ...

Page 407: ...FILTER CASE 7 6 CHECKING THE INTAKE FUNNELS 7 8 REMOVING THE AIR FILTER CASE AND INTAKE FUNNELS 7 8 INSTALLING THE AIR FILTER CASE AND INTAKE FUNNELS 7 9 THROTTLE BODIES 7 11 CHECKING THE INJECTORS 7 14 INSTALLING THE INJECTORS 7 14 CHECKING THE INJECTOR PRESSURE 7 14 CHECKING AND CLEANING THE THROTTLE BODIES 7 15 ADJUSTING THE THROTTLE POSITION SENSOR 7 16 ADJUSTING THE ACCELERATOR POSITION SENSO...

Page 408: ... California 5 Canister 1 For California only 6 Canister purge hose 1 Disconnect For California only 7 Canister breather hose 1 For California only 8 Rider seat bracket 1 9 Fuel pump coupler 1 Disconnect 10 Fuel hose 1 Disconnect 11 Filler cover 1 12 Fuel overflow hose 1 6 4 11 8 16 6 18 9 20 7 6 19 1 2 5 3 4 14 13 4 17 LT LT 12 15 10 21 LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ib...

Page 409: ...ank protector 1 For installation reverse the removal proce dure Removing the fuel tank Order Job Parts to remove Q ty Remarks 6 4 11 8 16 6 18 9 20 7 6 19 1 2 5 3 4 14 13 4 17 LT LT 12 15 10 21 LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 41 Nm 4 1 m kgf 30 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 New New ...

Page 410: ... frame with fuel tank TIP Leave the fuel tank mounted in the rear frame when removing the rear frame EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS2S31082 ...

Page 411: ...install the fuel tank and rear frame as a unit 2 Connect Fuel hose Fuel pump coupler NOTICE ECA2S31061 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To ...

Page 412: ... and adapter 3 to the fuel hose 1 d Start the engine e Measure the fuel pressure Faulty Replace the fuel pump Pressure gauge 90890 03153 YU 03153 Fuel pressure adapter 90890 03176 YM 03176 Fuel line pressure 324 0 kPa 3 24 kgf cm 47 0 psi 1 2 1 3 ...

Page 413: ...ect 5 Air induction system hose air filter case to air chamber 1 Disconnect 6 Upper air filter case 1 7 Fixed intake funnel 4 8 Lower air filter case 1 9 Lower air filter case gasket 4 10 Intake funnel servo motor 1 11 Variable intake funnel assembly 1 12 Variable intake funnel seal 4 13 Variable intake funnel holder shaft 1 14 Bushing 1 1 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 2 8 10 1 6 11 3 12 9 3 12...

Page 414: ... removal proce dure Removing the air filter case and intake funnels Order Job Parts to remove Q ty Remarks 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 2 8 10 1 6 11 3 12 9 3 12 6 Nm 0 6 m kgf 4 3 ft Ibf T R 8 13 10 14 15 4 5 New New LT 8 8 7 7 New 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 16 ...

Page 415: ...ts Damage wear Replace EAS2S31002 REMOVING THE AIR FILTER CASE AND INTAKE FUNNELS 1 Remove Upper air filter case TIP Loosen the upper air filter case screws in proper sequence as shown 2 Remove Intake funnel servo motor WARNING EWA2S31027 Handle the intake funnel servo motor with special care Never subject the intake funnel servo mo tor to strong shocks If the intake funnel servo motor is dropped ...

Page 416: ... Lower air filter case gaskets 1 TIP Make sure that the lower air filter case gaskets 1 are seated in the lower air filter case grooves 4 Check Variable intake funnel movement a Connect the intake funnel servo motor cou pler when installing the intake funnel servo motor into the lower air filter case b Set the main switch to the ON position The variable intake funnels 1 move into the down position...

Page 417: ... FILTER CASE 7 10 5 Install Upper air filter case TIP Tighten the upper air filter case screws in proper sequence as shown T R Upper air filter case screw 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 1 1 1 1 1 1 1 1 1 2 ...

Page 418: ...r coupler 1 Disconnect 5 Sub wire harness coupler 2 Disconnect 6 Fuel hose 1 Disconnect 7 Canister purge hose 1 Disconnect For California only 8 Coolant temperature sensor coupler 1 Disconnect 9 Throttle body joint clamp screw 4 Loosen 10 Throttle bodies 1 11 Throttle cable decelerator cable 1 Silver adjusting bolt 12 Throttle cable accelerator cable 1 Black adjusting bolt 13 Throttle body joint 4...

Page 419: ... installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks 1 8 10 11 12 3 4 5 7 6 14 13 13 2 9 9 9 13 13 9 8 14 3 Nm 0 3 m kgf 2 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 420: ...sconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Cylinder 3 injector coupler 1 Disconnect 8 Sub wire harness 1 9 Negative pressure hose 7 10 Canister purge hose 3 For California only 11 Injector joint 2 12 Fuel rail 1 13 Injector 4 For installation reverse the removal proce dure New New New New 1 9 9 2 3 13 9 10 10 10 9 13 13 12 11 New 11 7 6 8 5 4 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35...

Page 421: ...e 8 33 EAS2S31099 INSTALLING THE INJECTORS 1 Install a seal onto the end of each injector 2 Install the injectors to the injector joints 3 Install the fuel rail making sure to install them in the correct direction 4 Install the injector assemblies to the throttle bodies 5 Check the injector pressure after the injectors are installed to the throttle bodies Refer to CHECKING THE INJECTOR PRESSURE on...

Page 422: ...re place the throttle bodies as a set 2 Clean Throttle bodies NOTICE ECA2S31068 Observe the following precautions other wise the throttle bodies may not operate properly Do not open the throttle valves quickly Do not subject the throttle bodies to exces sive force Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution Do not apply cleaning solvent...

Page 423: ...m aged Do not allow carbon deposits or other for eign materials to enter any of the passages in each throttle body or in the space be tween the throttle valve shaft and the throt tle body f After removing the carbon deposits clean the inside of the throttle bodies with a petroleum based solvent and then dry the throttle bod ies using compressed air g Make sure that there are no carbon deposits or ...

Page 424: ... sen sor to strong shocks If the accelerator po sition sensor is dropped replace it 1 Check Accelerator position sensor Refer to CHECKING THE ACCELERATOR POSITION SENSOR on page 8 138 2 Adjust Accelerator position sensor angle a Temporary tighten the accelerator position sensor b Check that the throttle valves are fully closed c Connect the throttle position sensor acceler ator position sensor and...

Page 425: ...THROTTLE BODIES 7 18 1 ...

Page 426: ...AIR INDUCTION SYSTEM 7 19 EAS27040 AIR INDUCTION SYSTEM A A 6 5 4 5 6 1 4 3 3 2 1 A B C D ...

Page 427: ... to front reed valve cover A Install the air induction system hose air cut off valve to rear reed valve cover with its paint mark facing upward B Install the air induction system hose air cut off valve to front reed valve cover with its paint mark facing upward C Install the air induction system hose air cut off valve to rear reed valve cover with its paint mark facing outward D Install the air in...

Page 428: ...air chamber 1 4 Air induction system solenoid coupler 1 Disconnect 5 Air induction system hose air cut off valve to front reed valve cover 1 6 Air induction system hose air cut off valve to rear reed valve cover 1 7 Atmospheric pressure sensor coupler 1 Disconnect 8 Atmospheric pressure sensor 1 9 Grommet 1 10 Air cut off valve 1 11 Air cut off valve bracket 1 For installation reverse the removal ...

Page 429: ...emove Q ty Remarks Cylinder head covers Refer to CAMSHAFTS on page 5 9 1 Reed valve cover 2 2 Reed valve assembly 4 3 Reed valve plate 4 For installation reverse the removal proce dure 1 3 2 3 LT 1 3 2 3 LT 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 ...

Page 430: ...als from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens when the coolant temperature is below the specified value to allow the air to flow into the exhaust pipe assembly When the engine is warm the air cut off valve opens while the vehi cle is decelerating if the throttle grip is in the fully close position 1 Check Hoses Loose connections Connect prope...

Page 431: ... 8 13 CIRCUIT DIAGRAM 8 13 TROUBLESHOOTING 8 15 LIGHTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 36 DIAGNOSTIC MODE 8 37 TROUBLESHOOTING DETAILS 8 43 FUE...

Page 432: ...SWITCHES 8 121 CHECKING THE BULBS AND BULB SOCKETS 8 124 CHECKING THE FUSES 8 125 CHECKING AND CHARGING THE BATTERY 8 126 CHECKING THE RELAYS 8 129 CHECKING THE TURN SIGNAL HAZARD RELAY 8 130 CHECKING THE RELAY UNIT DIODE 8 130 CHECKING THE IGNITION COILS 8 131 CHECKING THE IGNITION SPARK GAP 8 132 CHECKING THE CRANKSHAFT POSITION SENSOR 8 132 CHECKING THE LEAN ANGLE SENSOR 8 133 CHECKING THE STAR...

Page 433: ......

Page 434: ... G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L S...

Page 435: ...19 Sidestand switch 20 Crankshaft position sensor 24 Lean angle sensor 30 ECU engine control unit 32 Cylinder 1 ignition coil 33 Cylinder 2 ignition coil 34 Cylinder 3 ignition coil 35 Cylinder 4 ignition coil 36 Spark plug 63 Gear position switch 83 Engine stop switch 89 Ignition fuse ...

Page 436: ...However the engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 12 6 3 8 1 Bat...

Page 437: ...3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 132 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 131 Replace the ignition coil s 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSIT...

Page 438: ...CHES on page 8 121 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 130 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 133 Replace the lean angle sensor 13 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem wir...

Page 439: ...IGNITION SYSTEM 8 6 ...

Page 440: ...Br W Br B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R ...

Page 441: ...se 7 Main switch 8 Battery 9 Frame ground 12 Starter relay 13 Starter motor 14 Relay unit 15 Starting circuit cut off relay 19 Sidestand switch 63 Gear position switch 68 Clutch switch 83 Engine stop switch 84 Start switch 89 Ignition fuse ...

Page 442: ...tor 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 13 1 12 4 5 7 7 7 7 7 a b 9 7 10 8 6 2 14 3 11 a WHEN THE TRANSMISSION IS...

Page 443: ...ation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 133 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 46 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 129 Replace the relay unit 6 Chec...

Page 444: ...switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the right handlebar switch 14 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 7 Prope...

Page 445: ...ELECTRIC STARTING SYSTEM 8 12 ...

Page 446: ...B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L ...

Page 447: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 6 Main fuse 8 Battery 9 Frame ground ...

Page 448: ...AND CHARGING THE BATTERY on page 8 126 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 134 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 134 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to C...

Page 449: ...CHARGING SYSTEM 8 16 ...

Page 450: ...B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L ...

Page 451: ...unction meter 58 Meter light 61 High beam indicator light 66 Headlight relay 69 Dimmer switch 76 Front right turn signal position light 77 Front left turn signal position light 79 Auxiliary light 80 Headlight 85 Tail brake light 87 License plate light 88 Signaling system fuse 89 Ignition fuse 90 Headlight fuse ...

Page 452: ...SOCKETS on page 8 124 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight ignition and sig naling system Refer to CHECKING THE FUS ES on page 8 125 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 126 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace t...

Page 453: ...LIGHTING SYSTEM 8 20 NG OK 7 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting sys tem wiring Replace the ECU or meter assembly 1 ...

Page 454: ... B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L...

Page 455: ...el level warning light 57 Coolant temperature warning light 59 Left turn signal indicator light 60 Right turn signal indicator light 62 Meter assembly 2 63 Gear position switch 64 Oil level switch 65 Turn signal hazard relay 70 Hazard switch 71 Turn signal switch 72 Horn switch 73 Rear right turn signal light 74 Rear left turn signal light 75 Horn 76 Front right turn signal position light 77 Front...

Page 456: ...eck the fuses Main ignition signaling system backup and ABS ECU Refer to CHECKING THE FUS ES on page 8 125 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 126 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch 4 Check the entire signaling system wiring R...

Page 457: ...lace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system wiring Replace the tail brake light assembly 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS...

Page 458: ...connect or repair the signaling system wiring Replace the meter assembly 1 1 Check the gear position switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the gear position switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 130 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair t...

Page 459: ...IL LEVEL SWITCH on page 8 135 Replace the oil level switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system wiring Replace the meter assembly 1 or meter assembly 2 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 135 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to C...

Page 460: ...ng system wiring Replace the ECU meter assembly 1 or meter assembly 2 1 Check that the shift timing indicator light is set to come on and that the brightness level of the light is ad justed properly Refer to FEATURES on page 1 2 Replace the meter assembly 1 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system wiring This c...

Page 461: ...SIGNALING SYSTEM 8 28 ...

Page 462: ... G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L S...

Page 463: ...ch 8 Battery 9 Frame ground 26 Coolant temperature sensor 30 ECU engine control unit 89 Ignition fuse 92 Radiator fan motor relay 93 Main radiator fan motor fuse 94 Main radiator fan motor 95 Sub radiator fan motor fuse 96 Sub radiator fan motor ...

Page 464: ...terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 136 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 129 Replace the radiator fan motor relay 6 Check the coolant tempe...

Page 465: ...COOLING SYSTEM 8 32 ...

Page 466: ... W Br B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W ...

Page 467: ...lerator position sensor 29 Throttle position sensor 30 ECU engine control unit 31 Air induction system solenoid 32 Cylinder 1 ignition coil 33 Cylinder 2 ignition coil 34 Cylinder 3 ignition coil 35 Cylinder 4 ignition coil 36 Spark plug 37 Throttle servo motor 38 Intake funnel servo motor 39 EXUP servo motor 40 Injector 1 41 Injector 2 42 Injector 3 43 Injector 4 44 Rear wheel sensor 47 ABS ECU e...

Page 468: ...r LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1...

Page 469: ...he faulty system with the fault code c Identify the probable cause of the malfunc tion 2 Check and repair the probable cause of mal function 3 Perform fuel injection system reinstatement action Refer to Reinstatement method of table in TROUBLESHOOTING DETAILS 4 Turn the main switch to OFF and back to ON then check that no fault code number is displayed TIP If fault codes are displayed repeat steps...

Page 470: ...r except the odometer displays DIAG appears on the odometer LCD 4 Simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the di agnostic mode The diagnostic code number D 01 appears on the clock LCD 5 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET buttons TIP To decrease the selected diagnostic code number pre...

Page 471: ...play Checking method D 01 Throttle position sensor signal 1 Fully closed position 15 16 Check with throttle valves fully closed Fully opened position 97 102 Check with throttle valves fully open D 02 Atmospheric pressure Displays the atmospheric pressure Compare the actually mea sured atmospheric pres sure with the meter display value D 03 Pressure difference atmospheric pressure and intake air pr...

Page 472: ...sensor signal 2 Fully closed position 15 16 Check with throttle valves fully closed Fully opened position 97 102 Check with throttle valves fully open D 14 Accelerator position sen sor signal 1 Fully closed position 15 16 Check with throttle grip fully closed Fully opened position 97 102 Check with throttle grip fully open D 15 Accelerator position sen sor signal 2 Fully closed position 15 16 Chec...

Page 473: ...ay repeats the same process D 62 Malfunction history code erasure No history 0 History exists Displays the total number of malfunctions including the current malfunction that have occurred since the history was last erased For example if there have been three malfunctions 03 is displayed To erase the history set the engine stop switch from to D 63 Malfunction code reinstate ment for fault code No ...

Page 474: ...Connect an ignition checker D 33 Cylinder 4 ignition coil Actuates the cylinder 4 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker D 34 Intake funnel servo motor Actuates the intake funnels up position down position for each 3 seconds Illuminates the engine trou ble warning light Check the operati...

Page 475: ...n the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel pump relay five times D 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the radiator fan motor re lay five times D 52 Headligh...

Page 476: ... No Meter display Checking method Probable cause of malfunction Check or maintenance job 1 Installed condition of cylinder identifica tion sensor Check for looseness or pinching 2 Connections Cylinder identification sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect...

Page 477: ...method Cranking the engine Fault code No 13 Item Intake air pressure sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D 03 Meter display Displays the intake air pressure Checking method Set the engine stop switch to and then push the start switch If the display value changes the performance is OK Probable cause of malfunction Chec...

Page 478: ...r malfunction at intermediate electrical potential Check and repair the connection Replace it if there is a malfunction 3 Connections Intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Reinstatement method Starting the engine...

Page 479: ...d ECU coupler black brown black brown white white black black blue green blue green 4 Defective throttle position sensor Execute the diagnostic mode Code No D 01 and or D 13 Replace if defective Refer to CHECKING THE THROTTLE POSI TION SENSOR on page 8 137 Reinstatement method Turning the main switch to ON Fault code No 17 Item EXUP servo motor circuit open or short circuit detected Fail safe syst...

Page 480: ...uble warning light Checking method Check the operating sound Probable cause of malfunction Check or maintenance job 1 Connections EXUP servo motor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 2 Open or short circuit in wire harness Repair or rep...

Page 481: ...ad 3 Defective sidestand switch Execute the diagnostic mode Code No D 20 Replace if defective Refer to CHECKING THE SWITCHES on page 8 121 Reinstatement method If the transmission is in gear retracting the sidestand If the transmission is in neutral reconnecting the wiring Fault code No 20 Item Intake air pressure sensor or atmospheric pressure sensor when the main switch is turned to ON the atmos...

Page 482: ...ant temperature sensor coupler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor...

Page 483: ...t Between intake air temperature sensor coupler and ECU coupler black blue black blue brown white brown white 4 Defective intake air temperature sensor Execute the diagnostic mode Code No D 05 Replace if defective Refer to CHECKING THE INTAKE AIR TEM PERATURE SENSOR on page 8 140 Reinstatement method Turning the main switch to ON Fault code No 23 Item Atmospheric pressure sensor open or short circ...

Page 484: ...tion of O2 sensor Check for looseness or pinching 2 Connections O2 sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and EC...

Page 485: ...ace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 133 Reinstatement method Turning the main switch to ON however the engine cannot be restarted unless the main switch is first turned OFF Fault code No 33 Item Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 ignition coil Fail safe system Able to start engine depending on the number of f...

Page 486: ...ignition coil open or short circuit detected in the primary lead of the cylinder 2 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No D 31 Actuator operation Actuates the cylinder 2 ignition coil five times at one second in tervals Illuminates the engine trouble warning...

Page 487: ...3 ignition coil open or short circuit detected in the primary lead of the cylinder 3 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No D 32 Actuator operation Actuates the cylinder 3 ignition coil five times at one second in tervals Illuminates the engine trouble warni...

Page 488: ...der 4 ignition coil open or short circuit detected in the primary lead of the cylinder 4 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No D 33 Actuator operation Actuates the cylinder 4 ignition coil five times at one second in tervals Illuminates the engine trouble w...

Page 489: ...eration Actuates the injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the injector 1 five times D 37 Actuator operation Actuates the injector 2 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the injector 2 five times D 38 Actuator oper...

Page 490: ...orange black orange black 3 Defective injector Execute the diagnostic mode Code No D 36 D 37 D 38 and or D 39 Replace if defective Refer to CHECKING THE INJECTORS on page 7 14 Reinstatement method Cranking the engine Connect the fuel injector couplers Fault code No 41 Item Lean angle sensor open or short circuit detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic co...

Page 491: ...r securely 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green blue blue blue green blue green 3 Defective lean angle sensor Execute the diagnostic mode Code No D 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 133 Reinstatement meth...

Page 492: ...ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between rear wheel sensor coupler and ABS ECU coupler white white black black Between ABS ECU coupler and ECU coupler white yel...

Page 493: ...ce if there is an open or short circuit Between gear position switch coupler and re lay unit coupler sky blue sky blue Between relay unit coupler and ECU coupler black yellow black yellow 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION on page 5 98 4 Defective gear position switch neutral circuit Execute the diagnostic mode Code No D 21 Replace if defective Re...

Page 494: ...nt method Starting the engine and operating it at idle Fault code No 44 Item EEPROM fault cylinder No an error is detected while reading or writing on EEPROM CO adjustment value Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No D 60 Meter display EEPROM fault code display 00 no history 01 04 Cylinder fault code history exists If more than one cylinder is ...

Page 495: ... charge the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 126 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYSTEM on page 8 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery terminal and main fuse cou pler red red Between main fuse coupler and main switch coupler red red Between main switc...

Page 496: ... fully opened position Checking method Check with throttle grip fully closed Check with throttle grip fully open Probable cause of malfunction Check or maintenance job 1 Installed condition of accelerator position sensor Check for looseness or pinching Check that the sensor is installed in the speci fied position 2 Connections Accelerator position sensor coupler Wire harness ECU coupler Check the ...

Page 497: ...02 fully opened position Checking method Check with throttle valve fully closed Check with throttle valve fully open Probable cause of malfunction Check or maintenance job 1 Installed condition of throttle position sensor Check for looseness or pinching Check that the sensor is installed in the speci fied position 2 Connections Throttle servo motor coupler Wire harness ECU coupler Check the couple...

Page 498: ...ostic code No Meter display Checking method Probable cause of malfunction Check or maintenance job 1 Connections Meter assembly 2 coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 2 Open or short circuit in wire harness Repair or replace if there is a...

Page 499: ... blue yellow blue 3 Malfunction in meter assembly 2 Replace the meter assembly 2 4 Malfunction in ECU Replace the ECU Reinstatement method Turning the main switch to ON Fault code No ER 3 Item ECU internal malfunction output signal error data from the ECU cannot be received correctly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Checking method Probab...

Page 500: ...coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly 2 coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly 2...

Page 501: ...FUEL INJECTION SYSTEM 8 68 ...

Page 502: ... B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B R W R W L...

Page 503: ...UMP SYSTEM 8 70 3 Fuel injection system fuse 6 Main fuse 7 Main switch 8 Battery 9 Frame ground 14 Relay unit 16 Fuel pump relay 17 Fuel pump 30 ECU engine control unit 83 Engine stop switch 89 Ignition fuse ...

Page 504: ...ean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 121 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 129 Replace the relay unit 6 Check the fuel pump Refer to ...

Page 505: ...FUEL PUMP SYSTEM 8 72 ...

Page 506: ... B Br W Br B G Y B B W L B L G B L L B L G B L ON OFF F WIRE HARNESS SUB WIRE HARNESS E WIRE HARNESS SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 W W W R R Br W L W1 R W B L B L B L B L R W W B L B Gy B R G W Y Y R Y W Y R Y W B W B...

Page 507: ...cut off relay 30 ECU engine control unit 44 Rear wheel sensor 45 Front wheel sensor 46 ABS test coupler 47 ABS ECU electronic control unit 51 ABS warning light 53 Multi function meter 62 Meter assembly 2 82 Front brake light switch 83 Engine stop switch 84 Start switch 85 Tail brake light 86 Rear brake light switch 88 Signaling system fuse 89 Ignition fuse 91 ABS ECU fuse ...

Page 508: ...4 A 2 1 ABS ECU fuse 2 ABS test coupler 3 Hydraulic unit assembly 4 ABS solenoid fuse 5 ABS motor fuse 6 ABS warning light 7 Front wheel sensor 8 Front wheel sensor rotor 9 Right front brake caliper 10 Left front brake caliper 11 Rear brake caliper 12 Rear wheel sensor 13 Rear wheel sensor rotor ...

Page 509: ...ABS ANTI LOCK BRAKE SYSTEM 8 76 ...

Page 510: ...BRAKE SYSTEM 8 77 EAS27750 ABS COUPLER LOCATION CHART B W B Br R Br B W Ch L W W Y Lg W B L B W G R Lg L Y L W Ch G Y R L GRAY W Gy BLACK B W BLACK W Gy BLACK B W BLACK R W Sb W G B B W Y Lg B G Y Lg L Lg W 2 1 3 5 4 ...

Page 511: ...ABS ANTI LOCK BRAKE SYSTEM 8 78 1 Meter assembly 1 coupler 2 ABS ECU coupler 3 Rear wheel sensor coupler 4 ABS test coupler 5 Front wheel sensor coupler ...

Page 512: ... perform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 115 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function 2 The ABS warning light comes on and then goes off when starting the engine ABS operation is normal The ...

Page 513: ... malfunction occurs EAS27800 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA2S31021 Perform the troubleshooting A B C D in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted Use sufficiently charged regular batteries only A Malfunction check using the ABS warning light B Detailed check of the malfunction The results o...

Page 514: ... is open C 5 Diagnose by the fault code D 1 Delete the fault codes D 2 Delete function test Finished B 5 Malfunctions are currently detected C 3 Does the ABS warning light remain on Connect the test coupler adapter to the ABS test coupler and then check for fault codes in the multi function display Are fault codes displayed in the multi function display TIP The ABS ECU fuse is blown The ABS ECU co...

Page 515: ...g light and all other indicator lights fail to come on C 2 EAS2S31066 B 2 THE ABS WARNING LIGHT FLASHES 1 Test coupler adapter Check if the test coupler adapter is connected to the ABS test coupler If the test coupler adapter is connected disconnect it and then install the protective cap onto the ABS test coupler If the test coupler adapter is not connected refer to B 5 MALFUNCTION ARE CURRENTLY D...

Page 516: ...apter is connected to the ABS test coupler the fault codes will be displayed in the multi function display Record all of the displayed fault codes 1 No fault codes are displayed in the multi function display and the ABS warning light is on C 3 2 No fault codes are displayed in the multi function display and the ABS warning light is flashing C 4 EAS2S31070 C 1 ONLY THE ABS WARNING LIGHT FAILS TO CO...

Page 517: ...erminal of the ABS ECU coupler If there is no continuity the wire harness is defective Properly repair or replace the wire harness Check for continuity between the black white terminal of the ABS ECU coupler and the ground If there is no continuity the wire harness is defective Properly repair or replace the wire harness 5 There is a break in the wire harness between the ABS ECU and the meter asse...

Page 518: ... the front wheel sensor is detected Installation of the front wheel sensor Front wheel Front wheel sensor housing Front wheel sensor rotor Hydraulic unit assembly ABS 14 ABS 27 Incorrect signal from the rear wheel sensor is detected Installation of the rear wheel sensor Rear wheel Rear wheel sensor housing Rear wheel sensor rotor Hydraulic unit assembly ABS 15 No continuity in the front wheel sens...

Page 519: ...ircuited Hydraulic unit assembly ABS 41 Front wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pressure Brake dragging Brake fluid Hydraulic unit operation tests Front wheel brake lines Hydraulic unit assembly ABS 42 ABS 47 Rear wheel will not recover from the locking tendency even though the sig nal is c...

Page 520: ...s detected in the front or rear wheel sensor when the vehicle is not being ridden ABS 54 Power voltage is too low Battery voltage Connection of the ABS ECU coupler and starter relay coupler Wire harness Refer to CHARGING SYSTEM on page 8 13 ABS 56 Hydraulic unit sensor power monitor circuit is abnormal Hydraulic unit assembly ABS 63 Front wheel sensor power is abnormal Front wheel sensor lead Wire...

Page 521: ...ff Perform a tri al run at a constant speed of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sen...

Page 522: ...g light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 24 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and s...

Page 523: ... come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if ...

Page 524: ...f the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visi ble damage replace the sensor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 5 ...

Page 525: ...terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness 5 ABS ECU 6 Front wheel sensor Fault code No AB...

Page 526: ...eel sensor circuit Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Connections Rear wheel sensor coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or c...

Page 527: ... terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness 5 ABS ECU 6 Rear wheel sensor Fault code No AB...

Page 528: ... Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform a tri al run at a constant speed of 30 km h and check that the ABS warning light does not come on 2 Foreign material inside sensor hous ing Check the interior of the sensor housing and t...

Page 529: ...g Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 3 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Fault code No ABS ...

Page 530: ...r 2 seconds then goes off Check that the ABS warning light comes on while the start switch is be ing pushed 2 Connections Starter relay coupler ABS ECU coupler Right handlebar switch coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore di...

Page 531: ...hen goes off Check that the ABS warning light does not flash when the front rear or both brakes are applied for 2 seconds or more 2 Connections ABS ECU coupler Front brake light switch connectors Rear brake light switch coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP T...

Page 532: ... Check the ABS solenoid fuse If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUS ES on page 3 34 3 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting ...

Page 533: ...tement confirmation method 1 Short circuit in solenoid relay Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal 2 Hydraulic unit assembly internal mal function Replace the hydraulic unit as sembly ...

Page 534: ...ABS motor fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire har ness Refer to CHECKING THE FUS ES on page 3 34 3 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switc...

Page 535: ...attery voltage is normal Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Rotation of wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates smoothly Check the front wheel axle for loose bearings and bends and the brake discs for distortion Refer to CHECKING THE FRONT BRAKE DISCS on page 4 34 Perform hy dra...

Page 536: ...om the brake master cylinder to the hydraulic unit and from the hydraulic unit to the left front brake caliper are correct See WARNING and TIP Fault code No ABS 41 Symptom Front wheel will not recover from the locking tendency even though the signal is continuous ly transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is normal Order Item components and probable ...

Page 537: ...rear brake hose connections are reversed on the hydraulic unit the pulsating action in the brake lever and brake pedal will be performed in the reverse order when the final check on page D 3 FINAL CHECK on page 8 115 is performed 5 Hydraulic unit assembly If the malfunction is not corrected after checking items 1 to 4 re place the hydraulic unit assembly Be sure to connect the brake hoses and coup...

Page 538: ...he hydraulic unit is normal 2 Brake master cylinder and brake cali per Check that the brake fluid pres sure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal is released 3 Brake fluid Visually check the brake fluid in the brake fluid reservoir for wa ter foreign materials solidifica tion and contamination Check for air in ...

Page 539: ...ront and rear brake hose connections are reversed on the hydraulic unit the pulsating action in the brake lever and brake pedal will be performed in the reverse order when the final check on page D 3 FINAL CHECK on page 8 115 is performed 5 Hydraulic unit assembly If the malfunction is not corrected after checking items 1 to 4 re place the hydraulic unit assembly Be sure to connect the brake hose ...

Page 540: ...of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal...

Page 541: ...sor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Fault code No ABS 51 ABS 52 Symptom Power voltage...

Page 542: ... off Perform a tri al run and check that the ABS warning light does not come on 2 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or connecting a coupler 3 Open or short circuit in wire harness Repai...

Page 543: ...e on 2 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or connecting a coupler 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Bet...

Page 544: ...ause Check or maintenance job Reinstatement confirmation method 1 Defective internal monitor circuit sen sor power Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal ...

Page 545: ...arness TIP Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in front wheel sensor lead Check that there is no short cir cuit between the gray terminal 3 and the white terminal 4 Check that there is no short cir cuit between the frame ground and the gray terminal 3 ...

Page 546: ... harness TIP Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in rear wheel sensor lead Check that there is no short cir cuit between the gray terminal 3 and the white terminal 4 Check that there is no short cir cuit between the frame ground and the gray terminal 3...

Page 547: ...functions have not been re paired Diagnose the malfunctions using the fault codes 8 Turn the main switch to OFF 9 Disconnect the test coupler adapter from the ABS test coupler and then install the protec tive cap onto the ABS test coupler Deleting the fault codes is now finished TIP Do not forget to install the protective cap onto the ABS test coupler NOTICE ECA2S31056 Since the fault codes remain...

Page 548: ...LEVEL on page 3 22 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 26 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 59 4 Delete the fault codes Refer to D 1 DELETING THE FAULT CODES on page 8 114 5...

Page 549: ...ABS ANTI LOCK BRAKE SYSTEM 8 116 ...

Page 550: ...ELECTRICAL COMPONENTS 8 117 EAS27972 ELECTRICAL COMPONENTS 1 3 4 5 6 7 8 11 10 9 12 13 14 21 20 17 18 19 15 16 22 2 23 ...

Page 551: ... box 1 9 Headlight relay 10 Radiator fan motor relay 11 Relay unit 12 Rear brake light switch 13 O2 sensor 14 Sidestand switch 15 Cylinder 1 ignition coil 16 Cylinder 2 ignition coil 17 Horn 18 Main radiator fan 19 Sub radiator fan 20 Cylinder 4 ignition coil 21 Cylinder 3 ignition coil 22 Intake air temperature sensor 23 Front brake light switch ...

Page 552: ...ELECTRICAL COMPONENTS 8 119 3 4 5 6 2 1 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Page 553: ...mbly 6 Fuse box 2 7 Rectifier regulator 8 EXUP servo motor 9 Fuel pump assembly 10 Gear position switch 11 Oil level switch 12 Crankshaft position sensor 13 Coolant temperature sensor 14 Cylinder identification sensor 15 Intake air pressure sensor 16 Throttle position sensor 17 Throttle servo motor 18 Accelerator position sensor 19 Intake funnel servo motor ...

Page 554: ...980 CHECKING THE SWITCHES L R Ch B Br Dg L B B G Br Y B Br W BLACK ON OFF B B Dg Br W Ch R Br L L B L Y Dg Br W Ch R W R L B W L W R W R L W G W B R G Sb L B B R Br L L B L Y L W B W Br B Br Y L B G B B BLACK 5 6 1 4 2 3 8 9 10 11 12 7 ...

Page 555: ...1 Dimmer switch 2 Hazard switch 3 Turn signal switch 4 Horn switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Rear brake light switch 9 Gear position switch 10 Sidestand switch 11 Main switch 12 Clutch switch ...

Page 556: ...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 switch posi...

Page 557: ...e Bulb WARNING EWA2S31015 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA2S31050 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the tran...

Page 558: ...ctor to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising...

Page 559: ...are 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 t...

Page 560: ... may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minut...

Page 561: ...ger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the batte...

Page 562: ...ket 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 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe R B Br R W R 2 1 4 3 W L Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative batte...

Page 563: ...cket tester DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal haza...

Page 564: ...og pocket tester YU 03112 C 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 probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 ...

Page 565: ...ON and engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a ...

Page 566: ... the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 10 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 check is likely to produce sparks therefore make sure n...

Page 567: ...own c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage EAS28180 CHECKING THE HORN 1 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the horn sound is obtained Stator coil resistance 0 184 0 276 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 568: ...to the fuel sender terminals as shown b Move the fuel sender float to minimum 3 and maximum 4 level position c Measure the fuel sender resistance Oil level switch resistance Maximum level position 484 536 Ω Minimum level position 114 126 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Maximum level position A Positive tester probe connector white 1 Negative tester probe body ground 2 M...

Page 569: ...Warning light is OK Warning light does not come on Replace the meter assembly 1 Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunc tion detected in oil level switch Replace the oil level switch EAS28250 CHECKING THE RADIATOR FAN MOTORS The following procedure applies to both of the radiator fan motors 1 Check Radiator fan motor Faulty rough movement Replace a...

Page 570: ...l care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle positio...

Page 571: ... angle properly Refer to ADJUSTING THE ACCELERATOR POSITION SENSOR on page 7 17 EAS28370 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester Ω 1 to the air in duction system solenoid terminals as shown c Measure the air induct...

Page 572: ...rankshaft d Measure the voltage of white black and black blue Turn the crankshaft twice and check that the output voltage rises to approx imately 4 8 V once EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR WARNING EWA2S31019 Handle the intake air pressure sensor with special care Never subject the intake air pressure sen sor to strong shocks If the intake air pres sure sensor is dropped replace it...

Page 573: ...ake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the in take air temperature sensor terminals as shown b Immerse the intake air temperature sensor 1 in a container filled with water 2 TIP Make sure that the intake air temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down ...

Page 574: ...ELECTRICAL COMPONENTS 8 141 ...

Page 575: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 576: ...ty 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 4 Ignition coil s Cracked or broken igniti...

Page 577: ...de 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 EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled...

Page 578: ...hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level h...

Page 579: ...life expired Tail brake light does not come on Wrong tail brake light LED Too many electrical accessories Incorrect connection Burnt out tail brake light LED Tail brake light bulb burnt out Wrong tail brake light LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Bu...

Page 580: ...witch 64 Oil level switch 65 Turn signal hazard relay 66 Headlight relay 67 Left handlebar switch 68 Clutch switch 69 Dimmer switch 70 Hazard switch 71 Turn signal switch 72 Horn switch 73 Rear right turn signal light 74 Rear left turn signal light 75 Horn 76 Front right turn signal position light 77 Front left turn signal position light 78 Headlight assembly 79 Auxiliary light 80 Headlight 81 Rig...

Page 581: ......

Page 582: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 583: ...S SUB WIRE HARNESS D WIRE HARNESS RADIATOR FAN MOTOR SUB WIRE HARNESS C WIRE HARNESS METER ASSEMBLY 1 SUB WIRE HARNESS B WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 2 A WIRE HARNESS IGNITION COIL SUB WIRE HARNESS 1 D D C F F F C C D C F E C E E A A B A A B B B D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 36 36 36 37 38 39 40 41 42 43 44 45 46...

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