Yamaha XT1200Z(Z) 2010 Service Manual Download

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IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the frame.

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.

Summary of Contents for XT1200Z(Z) 2010

Page 1: ...2010 SERVICE MANUAL XT1200Z Z 23P 28197 E0 ...

Page 2: ...200Z Z 2010 SERVICE MANUAL 2010 by Yamaha Motor Co Ltd First edition March 2010 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

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

Page 5: ...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: ...ND ABS OPERATION 1 20 ABS SELF DIAGNOSIS FUNCTION 1 24 ABS WARNING LIGHT AND OPERATION 1 26 OUTLINE OF THE TCS Traction Control System 1 28 INSTRUMENT FUNCTIONS 1 31 IMPORTANT INFORMATION 1 37 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 37 REPLACEMENT PARTS 1 37 GASKETS OIL SEALS AND O RINGS 1 37 LOCK WASHERS PLATES AND COTTER PINS 1 37 BEARINGS AND OIL SEALS 1 38 CIRCLIPS 1 38 BASIC SERVICE INFORMA...

Page 10: ...0 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame 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: ...engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times b...

Page 12: ...CU Signals that are input from the throttle position sensor accelerator position sensor coolant temperature sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensors enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a res...

Page 13: ...respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability ...

Page 14: ... 6 4 3 2 1 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU engine control unit 5 YCC T CPU 6 FI CPU 7 Sensor input 8 Neutral switch 9 Crankshaft position sensor 10 Rear wheel sensor 11 Coolant temperature sensor ...

Page 15: ...ever if the brake pedal is operated while the UBS is operating the UBS will continue to operate until the brake pedal input exceeds the rear brake force generated by the UBS Then the rear braking will switch to rider control TIP If the brakes are operated while the vehicle is traveling at low speeds the UBS will only generate a small brake force UBS operation Brake lever input only Front braking a...

Page 16: ...ally pressurized until the second input exceeds the automatic pressurization B Brake pedal is operated before brake lever a First input b Second input d No automatic pressurization a b c a d b A B a a 2 1 b b c b b b 3 6 5 4 1 Rear brake master cylinder 2 Front brake master cylinder 3 Hydraulic unit assembly ABS ECU 4 Right front brake caliper 5 Left front brake caliper 6 Rear brake caliper a Inpu...

Page 17: ...ver is released then squeezed again the UBS will not operate NOTICE ECA23P1055 The unified brake system is a system to assist the brake operation However both the brake lever and the brake pedal must be operated for maximum braking effect Because the balance between the front brake calipers and the rear brake caliper in the unified brake system is determined electronically be sure to use the speci...

Page 18: ...d A 0 20 40 60 80 100 120 140 f h g B a Hydraulic pressure distribution b Rear brake output bars c Front brake input bars d Rider only e When carrying the maximum load f Vehicle speed coefficient g Coefficient h Speed km h ...

Page 19: ...ut hydraulic pressure from the brake lever or brake pedal 2 If the wheels have a tendency to lock during brake lever input brake pedal input or UBS control the ABS will operate 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout A A 12 1 2 3 6 7 8 9 10 11 12 13 4 5 1 ABS warning light 2 Front wheel sens...

Page 20: ...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 21: ... wheel 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 hydraulic pressure in the brake caliper Once the ABS ECU determines that the tendency of the wheel to lock has diminished after the hydraulic pressure is reduced it increa...

Page 22: ...lip sideways WARNING EWA23P1023 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 vehicles equipped with ABS cannot be prevented from falling over if braked sud denly The ABS functions to prevent the tendency of the wheel to lock by controlling t...

Page 23: ...ons Also there may be little or no additional rear brake force provided by the UBS If the UBS does not operate the front and rear brakes will oper ate independently according to the rider input and the respective brake force will be the same as during normal braking When the brake lever is squeezed only the front brakes will operate and when the brake pedal is depressed only the rear brake will op...

Page 24: ...n the MR sensor installed in the wheel sensor generates the voltage which is proportional to the magnetic flux density and the generated volt age is processed for waveform shaping in the MR sensor to output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 10 7 7 13 13 5 6 3 4 15 14 14 16 17 12 12 11 9 9 8 1 Front brake master cylinder 2 Rear brake master cylinde...

Page 25: ...rning light is disconnected and check if the ABS is operating prop erly NOTICE ECA23P1056 If the rear wheel is raced with the vehicle on the centerstand the ABS warning light may flash or come on If this occurs set the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle is ridden 2 2 1 1 7 3 7 4 5 8 8 6 3 At low speed 4 At high speed 5...

Page 26: ... open during normal braking and UBS operation The valve opens and closes during ABS operation to adjust the hydraulic pressure input from the brake lever or brake pedal 2 Outlet solenoid valve This valve is closed during normal braking and UBS operation The valve opens during ABS operation to reduce the hydraulic pressure 3 Separation solenoid valve This valve is open when the brake pedal is depre...

Page 27: ... 9 10 11 12 13 17 15 26 22 24 25 23 28 29 30 31 32 33 18 19 20 21 16 27 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 assembly 13 ABS ECU 14 Solenoid relay 15 ABS motor relay 16 Front brake inlet solenoid 17 Front brake outlet so...

Page 28: ...e can be heard from under the seat and if the brake lever or brake pedal is even slightly operated a vibration can be felt at the lever and pedal but these do not indicate a malfunction 2 1 3 4 5 6 7 8 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operation 8 Depressurize pressurize ...

Page 29: ...nt brake master cylinder Rear brake When the ABS is not activated the inlet solenoid valve and separation solenoid valve are open and the outlet solenoid valve and shuttle solenoid valve are closed because a control signal has not been trans mitted from the ABS ECU Therefore when the brake pedal is depressed the hydraulic pressure in the rear brake master cylinder increases and the brake fluid is ...

Page 30: ...izing phase The outlet solenoid valve is closed by the pressurization signal transmitted from the ABS ECU At this time the ABS ECU controls the opening of the inlet solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 3 7 7 b 10 b c d c 11 11 14 15 13 13 12 9 9 8 2 4 a a 10 5 6 A B 1 Front br...

Page 31: ...ed because a control signal has not been transmitted from the ABS ECU The shuttle solenoid valve opens and closes according to the UBS control signals from the ABS ECU The hydraulic pump draws in the brake fluid from the rear brake master cylinder and automatically pressurizes the rear brake caliper If the brake pedal is depressed the UBS automatic pressurization stops The ABS ECU detects and cont...

Page 32: ...sure sensor and the separation solenoid valve and shuttle solenoid valve open and close The brake fluid stored in the buffer chamber is pumped back to the rear brake master cylinder by the hydraulic pump linked to the ABS motor 1 3 8 11 8 d 12 12 5 13 13 17 18 16 15 15 14 10 10 2 4 a 9 e c f b 6 7 A B 1 Front brake master cylinder 2 Brake lever 3 Rear brake master cylinder 4 Brake pedal 5 Rear bra...

Page 33: ...nosis then goes off if there are no problems 2 The ABS warning light comes on while the start switch is being pushed When the engine is being started the ABS warning light comes on while the start switch is being pushed Refer to ELECTRIC STARTING SYSTEM on page 8 7 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 ABS self diagnosis b c d ...

Page 34: ...iding If the ABS warning light flashes while riding there is no problem with the function of the ABS and UBS However the ABS ECU input has unstable factors For details refer to ABS TROUBLE SHOOTING OUTLINE on page 8 95 TIP The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler 5 The ABS warning light 1 flashes when the te...

Page 35: ... the rear wheel is raced with the vehicle on the centerstand the ABS warning light may flash or come on If this occurs set the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off when the vehicle first starts off after the main switch was set back to ON The ABS operation is normal if the ABS warning light flashes If the ABS warning light comes on or fla...

Page 36: ... cornering performance 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 sudden braking is liable to caus...

Page 37: ...TCS Traction control system layout TCS Traction control system block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds If the amount of slip exceeds the preset value the ECU controls the ignition timing fuel cut off and throttle valv...

Page 38: ...ent loss of traction due to excessive speed when entering turns when accelerating hard at a sharp lean angle or while braking and cannot prevent front wheel slip ping As with any motorcycle approach surfaces that may be slippery with caution and avoid especially slippery surfaces There are two traction control system modes The traction control system can also be turned off TCS mode 1 Default mode ...

Page 39: ... the traction control system switch on the multi function meter for less than one second to change between TCS modes 1 and 2 Push the switch for at least two seconds to select TCS Off and turn the traction control system off Push the switch again to return to the previously selected mode 1 or 2 Resetting The traction control system will be disabled in the following condition The rear wheel is rota...

Page 40: ...set buttons located under the display allow you to control or change the set tings in the multi function meter unit TIP To use the left and right buttons the key must be turned to ON except for the brightness mode For the U K only To switch the speedometer and odometer tripmeter fuel consumption dis plays between kilometers and miles press the left button for at least two seconds Tachometer The el...

Page 41: ...r manually it re sets itself automatically and the display returns to the prior mode after refueling and traveling 5 km 3 mi Clock The clock displays when the key is turned to ON In addition the clock can be displayed for 10 seconds by pushing the left button when the main switch is in the OFF LOCK or Parking position To set the clock 1 Push the left button and right button together for at least t...

Page 42: ...ntake temperature mode the cool ant temperature mode the instantaneous fuel consumption mode km L L 100 km or MPG and the average fuel consumption mode AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG in the following order air intake temperature coolant temperature km L L 100 km or MPG AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG air in take temperature Air intake temperature mode The air intak...

Page 43: ... display shows the aver age distance that can be traveled on 1 0 L of fuel The AVE_ _ _ L 100 km display shows the average amount of fuel necessary to travel 100 km For the UK only The AVE_ _ _ MPG display shows the average distance that can be trav eled on 1 0 Imp gal of fuel To switch between the average fuel consump tion displays push the right button when one of the displays is shown To reset ...

Page 44: ...tarts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re reg istering key and both standard keys If the display indicates any fault codes note the code number and then check the vehicle NOTICE EWA23P1042 If the display indicates a fault code the vehi cle should be checked as soon as possible in o...

Page 45: ...d range to the high speed range Sports mode S This mode offers a sportier engine response in the low to mid speed range compared to the touring mode Drive mode switch MODE WARNING EWA23P1043 Do not change the D mode while the vehicle is moving Using this switch changes the drive mode to touring mode T or sports mode S The throttle grip must be completely closed in or der to change the drive mode T...

Page 46: ... 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 47: ...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 48: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 49: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 50: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 51: ...ure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If ...

Page 52: ...er or connector to gether until they are connected securely 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 4 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 90890 03132 ...

Page 53: ... When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Test coupler adapter 90890 03149 1 25 4 72 4 73 Pocket tester 90890 03132 1 43 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 6 5 61 Valve lapper 908...

Page 54: ... 26 Oil pressure adapter B 90890 03124 3 26 Fork spring compressor 90890 01441 YM 01441 4 85 4 90 Damper rod holder 90890 01423 Damping rod holder YM 01423 4 86 4 88 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 87 4 88 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 89 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 55: ...1548 4 110 Final gear backlash band 90890 01511 Middle drive gear lash tool YM 01230 4 110 Coupling gear holding tool 90890 01560 4 112 4 116 Bearing retainer wrench 90890 01561 4 112 4 116 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 118 Tool name Tool No Illustration Reference pages YM A8703 ø75 ø65 6 0 YM A9409 7 YM A5142 4 ...

Page 56: ...33223 5 1 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 9 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 17 5 20 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 23 5 47 5 88 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 Tool name To...

Page 57: ...Valve guide reamer 5 5 mm 90890 01196 YM 01196 5 32 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 38 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 45 5 46 5 70 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 45 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 50 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 58: ...er bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 109 Weight 90890 01084 YU 01083 3 5 109 Universal joint holder 90890 04160 5 117 5 119 Damper spring compressor 90890 04090 5 117 5 119 Tool name Tool No Illustration Reference pages YU 01083 3 90890 04160 25 20 30 25 30 24 20 24 ...

Page 59: ...e drive gear holder YM 33222 5 121 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 9 Tool name Tool No Illustration Reference pages YM 04054 YU 24460 A YU 33984 ...

Page 60: ...apter 90890 03176 YM 03176 7 11 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 8 130 8 131 8 139 8 140 8 141 8 145 8 146 8 147 8 148 8 149 8 150 8 151 8 152 8 153 8 154 8 155 8 156 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 148 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 149 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 154 Tool name To...

Page 61: ...TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ENGINE 2 28 CHASSIS 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING 2 43 ...

Page 62: ...88 8 in Overall width 980 mm 38 6 in Overall height 1410 mm 55 5 in Seat height 845 mm 33 3 in low position 870 mm 34 3 in high position Wheelbase 1540 mm 60 6 in Ground clearance 205 mm 8 07 in Minimum turning radius 2700 mm 106 3 in Weight With oil and fuel 261 kg 575 lb Maximum load total weight of rider passenger cargo and accessories 209 kg 461 lb ...

Page 63: ...type or higher JASO standard MA Engine oil quantity Total amount 4 20 L 4 44 US qt 3 70 Imp qt Without oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt With oil filter cartridge replacement 3 40 L 3 59 US qt 2 99 Imp qt Oil pressure 65 0 kPa 1100 r min 0 65 kgf cm 1100 r min 9 4 psi 1100 r min at oil temperature of 65 0 75 0 C 149 00 167 00 F Final gear oil Type Yamaha genuine shaft ...

Page 64: ...ght 320 0 mm 12 60 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 48 48 1 000 Impeller shaft tilt limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK CPR8EB9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 50 17 51 57 cm 3 06 3 15 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive right Camshaft cap ins...

Page 65: ...28 1 4606 in Valve head diameter A exhaust 30 90 31 10 mm 1 2165 1 2244 in Valve face width B intake 2 050 2 480 mm 0 0807 0 0976 in Valve face width B exhaust 2 050 2 480 mm 0 0807 0 0976 in Valve seat width C intake 1 10 1 30 mm 0 0433 0 0512 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 1 00 1 40 mm 0 0394 0 0551 in Valve margin thickness D exhaust ...

Page 66: ...0 in Installed length intake 32 00 mm 1 26 in Installed length exhaust 32 00 mm 1 26 in Spring rate K1 intake 25 00 N mm 2 55 kgf mm 142 75 lb in Spring rate K2 intake 32 53 N mm 3 32 kgf mm 185 75 lb in Spring rate K1 exhaust 25 00 N mm 2 55 kgf mm 142 75 lb in Spring rate K2 exhaust 32 53 N mm 3 32 kgf mm 185 75 lb in Installed compression spring force intake 192 00 220 00 N 19 58 22 43 kgf 43 1...

Page 67: ...Barrel Dimensions B T 1 20 3 45 mm 0 05 0 14 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 0047 in 2nd ring Ring type Taper Dimensions B T 1 20 4 20 mm 0 04 0 17 in End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 m...

Page 68: ... 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 1110 in Plate quantity 8 pcs Friction plate 3 thickness 2 90 3 10 mm 0 144 0 122 in Wear limit 2 80 mm 0 1110 in Plate quantity 1 pc Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring height 6 78 mm 0 27 in Minimum height 6 44 mm 0 25 in Spring quantity 1 pc Long clutch ...

Page 69: ...73 V Accelerator position sensor Resistance 1 20 2 80 kΩ Output voltage 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 336 504 Ω at 20 C 68 F Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa Intake air temperature sensor resistance 5 40 6 60 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F Coolant temperature sensor resistance 5 21 6 37 kΩ at 0 C 32 F 290 354 Ω at ...

Page 70: ...ENGINE SPECIFICATIONS 2 9 Final gear backlash 0 20 0 40 mm 0 008 0 016 in ...

Page 71: ...n Front tire Type Tubeless Size 110 80R19M C 59V Manufacturer model BRIDGESTONE BW 501 METZELER TOURANCE EXP FRONT C Wear limit front 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Rear tire Type Tubeless Size 150 70R17M C 69V Manufacturer model BRIDGESTONE BW 502 METZELER TOURANCE EXP C Wear limit rear 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Tire air pressure measured on cold tires Loading condition 0...

Page 72: ...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 Master cylinder inside diameter 12 70 mm 0 50 in Release cylinder inside diameter 29 6 mm 1 17 in Steering Steering bearing type Taper roller bearing Center to lock angle left 39 0 Center to lock angle right 39 0 Front suspension Type Telescopi...

Page 73: ...rber type Coil spring gas oil damper Rear shock absorber assembly travel 70 0 mm 2 76 in Spring free length 213 0 mm 8 39 in Installed length 203 0 mm 7 99 in Spring rate K1 132 30 N mm 13 49 kgf mm 755 43 lb in Spring stroke K1 0 0 70 0 mm 0 00 2 76 in Optional spring available No Enclosed gas air pressure STD 1600 kPa 16 0 kgf cm 227 6 psi Spring preload adjusting positions Minimum 6 Standard 4 ...

Page 74: ...0 168 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage 14 2 14 8 V Rectifier capacity 50 0 A Battery Model YTZ12S Voltage capacity 12 V 11 0 Ah Manufacturer GS YUASA Ten hour rate amperage 1 10 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 W 2 Auxiliary light 12 V 5 0 W 2 Tail brake light LED Front turn si...

Page 75: ...age 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No 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 180 0 Ω Headlight relay Coil resistance 96 00 Ω Throttle servo motor ...

Page 76: ...FICATIONS 2 15 ABS solenoid fuse 20 0 A Backup fuse 7 5 A Electronic throttle valve fuse 7 5 A Accessory light fuse OPTION 20 0 A Spare fuse 30 0 A Spare fuse 20 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 3 0 A ...

Page 77: ... 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 78: ...gf 7 2 ft lbf Throttle body joint clamp screw M5 2 3 0 Nm 0 30 m kgf 2 2 ft lbf Intake air pressure sensor screw M5 1 3 5 Nm 0 35 m kgf 2 5 ft lbf Accelerator position sensor bolt M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Throttle position sensor bolt M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Fuel rail screw M5 1 5 Nm 0 5 m kgf 3 6 ft lbf Radiator outlet pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Radiator outlet h...

Page 79: ...t M10 1 65 Nm 6 5 m kgf 47 ft lbf Crankshaft position sensor hold er bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Cylinder head cover bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Cylinder head breather plate bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Ignition coil bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Spark plug M10 4 13 Nm 1 3 m kgf 9 4 ft lbf Camshaft cap bolt M6 12 10 Nm 1 0 m kgf 7 2 ft lbf Intake camshaft sprocket ...

Page 80: ...t M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Main galley bolt M16 1 8 Nm 0 8 m kgf 5 8 ft lbf Sub galley bolt M20 1 8 Nm 0 8 m kgf 5 8 ft lbf Oil nozzle 1 bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Oil nozzle 2 M6 1 0 5 Nm 0 05 m kgf 0 36 ft lbf Oil nozzle 3 M8 1 3 0 Nm 0 30 m kgf 2 2 ft lbf Oil filter cartridge M20 1 17 Nm 1 7 m kgf 12 ft lbf Oil filter cartridge union bolt M20 1 80 Nm 8 0 m kgf 58 ft lbf Oil del...

Page 81: ... bolt M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Shift drum retainer screw M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kgf 16 ft lbf Connecting rod nut M9 4 See TIP Middle gear side cover screw M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Middle gear side cover damper plate screw M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt middle gear M8 1 20 Nm 2 0 m kgf 14 ft lbf Middle dr...

Page 82: ...hten the crankcase bolts 1 6 further to reach the specified angle 90 100 Tighten the crankcase bolts 7 32 7 21 30 32 24 Nm 2 4 m kgf 17 ft lbf 22 29 10 Nm 1 0 m kgf 7 2 ft lbf TIP Connecting rod nut Tighten the connecting rod bolts to 20 Nm 2 0 m kgf 14 ft lbf and then tighten them further to reach the specified angle 145 155 9 3 2 10 4 6 11 12 7 8 1 13 15 16 17 18 19 20 21 22 24 25 26 27 28 29 14...

Page 83: ...0 45 m kgf 3 3 ft lbf Muffler protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Brake pedal bolt M8 1 26 Nm 2 6 m kgf 19 ft lbf Shift pedal bolt M8 2 30 Nm 3 0 m kgf 22 ft lbf Shift arm bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Shift rod locknut shift arm side M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Shift rod locknut shift pedal side M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Left hand thread Radiator bolt M6 2 7 Nm 0 7 m kgf ...

Page 84: ...m kgf 5 1 ft lbf Hydraulic unit brake pipe flare nut M10 8 16 Nm 1 6 m kgf 12 ft lbf Tail brake light assembly bolt M6 2 15 Nm 1 5 m kgf 11 ft lbf Tail brake light assembly bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Tail brake light unit screw M6 1 0 4 Nm 0 04 m kgf 0 29 ft lbf Tail brake light unit screw M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf License plate light bolt M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Rear re...

Page 85: ...lbf Upper handlebar holder bolt M8 4 28 Nm 2 8 m kgf 20 ft lbf Steering stem nut M24 1 130 Nm 13 m kgf 94 ft lbf Lower ring nut M28 1 See TIP Horn bolt M6 2 14 Nm 1 4 m kgf 10 ft lbf Front brake hose holder and horn nut M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Front fender bolt front side M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front reflector nut M6 2 3 8 N...

Page 86: ...7 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bleed screw M7 1 6 Nm 0 6 m kgf 4 3 ft lbf Rear brake hose union bolt M10 4 30 Nm 3 0 m kgf 22 ft lbf Rear brake hose holder and swingarm bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose holder and frame bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake torque rod bolt M8 2 30 Nm 3 0 m kgf 22 ft lbf Re...

Page 87: ...al gear oil filler bolt M14 1 23 Nm 2 3 m kgf 17 ft lbf Ring gear bearing housing bolt M10 2 40 Nm 4 0 m kgf 29 ft lbf Ring gear bearing housing bolt M8 6 23 Nm 2 3 m kgf 17 ft lbf Coupling gear nut M20 1 150 Nm 15 m kgf 108 ft lbf Stake Bearing retainer M75 1 130 Nm 13 m kgf 94 ft lbf Left hand thread Final driven pinion gear bearing holder screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Ring gear stopper b...

Page 88: ...TIGHTENING TORQUES 2 27 2 1 ...

Page 89: ...s Decompression camshaft moving point Oil pump rotors inner and outer Crankcase bolt O rings balancer shaft journal Rear balancer holder Torque limiter Starter clutch idle gear shaft Starter clutch gear Primary driven gear clutch housing Thrust washer Spacers Long clutch push rod Short clutch push rod Ball Clutch boss nut thread and conical spring washer Transmission gears wheel and pinion and col...

Page 90: ...splines Ring gear bearing Yamaha genuine shaft drive oil SAE 80 API GL 5 or SAE 80 API GL 4 Hypoid gear oil Drive shaft splines Universal joint bearing Drive shaft oil seal Cylinder head cover and gasket Three bond No 1541C Cylinder head and 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 121...

Page 91: ... to metal moving parts Centerstand spring hook metal to metal moving parts Sidestand pivoting point and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and link contact point Tube guide throttle grip inner surface and throttle cables Brake lever pivoting point brake master cylinder push rod contact surface and metal to metal moving parts Clutch lever pivoting poi...

Page 92: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 1 8 2 3 4 5 7 6 9 10 11 13 14 12 15 16 17 18 19 A A ...

Page 93: ... pump scavenging 5 Oil pump feed 6 Relief valve 7 Oil filter cartridge 8 Front balancer shaft 9 Main gallery 10 Crankshaft 11 Oil nozzle 1 12 Timing chain tensioner 13 Intake camshaft 14 Exhaust camshaft 15 Rear balancer shaft 16 Main axle 17 Shift fork upper guide bar 18 Drive axle 19 Middle driven pinion gear ...

Page 94: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS Cylinder right side view and crankshaft rear view 6 7 8 1 5 1 2 16 9 10 11 12 15 14 13 2 3 4 ...

Page 95: ...Cylinder 4 Upper crankcase 5 Timing chain tensioner 6 Intake camshaft 7 Exhaust camshaft 8 Exhaust camshaft cap 9 Oil nozzle 1 10 Crankshaft 11 Main gallery bolt 12 Lower crankcase 13 Starter clutch gear 14 Generator rotor bolt 15 Generator rotor cover 16 Starter clutch idle gear ...

Page 96: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 Crankcase top view and transmission front view 1 2 1 2 3 4 5 6 9 5 8 7 ...

Page 97: ...CATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil filter cartridge 2 Oil delivery passage cover 3 Front balancer shaft 4 Crankshaft 5 Drive axle 6 Middle driven pinion gear 7 Lower crankcase 8 Oil pan 9 Main axle ...

Page 98: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 Oil pump right side view A A A B B 7 1 1 4 4 6 5 6 2 3 ...

Page 99: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Shift fork C 2 Shift fork R 3 Shift fork L 4 Oil pump assembly 5 Oil pan 6 Oil strainer oil pump 7 Shift fork upper guide bar ...

Page 100: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 Oil pump left side view 8 2 1 3 4 5 6 7 ...

Page 101: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil pump assembly 2 Oil filter cartridge 3 Oil strainer cover 4 Oil strainer oil pan 5 Oil pan 6 Lower crankcase 7 Upper crankcase 8 Rear balancer shaft ...

Page 102: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20420 COOLING SYSTEM DIAGRAMS 4 2 5 1 4 2 3 8 7 6 3 4 ...

Page 103: ...COOLING SYSTEM DIAGRAMS 2 42 1 Radiator cap 2 Radiator inlet hose 3 Radiator outlet hose 4 Radiator 5 Thermostat 6 Radiator outlet pipe 7 Water pump inlet hose 8 Water pump ...

Page 104: ...CABLE ROUTING 2 43 EAS20430 CABLE ROUTING Headlight assembly front and rear view A B C D E F G 1 2 1 2 2 2 2 2 3 4 5 6 6 7 8 9 6 ...

Page 105: ...ic locking tie forward D Route the headlight sub wire harness auxiliary DC jack lead front left turn signal light lead front right turn signal light lead and meter assembly lead though the hole in the headlight assembly bracket E Route the meter assembly lead to the rear of the headlight sub wire harness Make sure that the meter assembly lead crosses the headlight sub wire harness between the hold...

Page 106: ...CABLE ROUTING 2 45 Handlebar front view A B C D E F G H I J K L L L 1 1 2 5 5 3 4 5 7 9 1 1 1 1 5 5 5 5 6 6 6 7 8 10 9 G M N O 6 6 ...

Page 107: ...e the immobilizer unit lead over the guide as shown in the illustration G Face the buckle of the plastic band forward with the end pointing downward Do not cut off the excess end of the plastic band H Fasten the horn lead with a plastic locking tie so that the lead does not contact the horn Be sure to fasten the plastic locking tie around the protective sleeve of the lead not the lead itself I Pos...

Page 108: ...ont brake hose left side view A B C 1 1 1 2 3 3 3 3 4 4 4 4 7 7 8 2 2 2 5 6 6 9 9 10 10 11 11 12 12 13 4 8 8 4 4 6 8 J K K L D E F G H I M N O P Q Q Q R S T U V 8 7 8 8 8 7 7 7 W X Y Z 14 14 AA AB AC AD AD AE AF AG AH AI AJ ...

Page 109: ...ottle cable housing K Route the throttle cables to the outside of the leads L Route the horn lead to the inside of the throttle cables M Route the immobilizer unit lead to the inside of the throttle cables Fasten the immobilizer unit lead at the purple tape with the holder N Face the catch of the holder downward O Fasten the front wheel sensor lead immobilizer unit lead and horn lead at the white ...

Page 110: ...ont brake hose left side view A B C 1 1 1 2 3 3 3 3 4 4 4 4 7 7 8 2 2 2 5 6 6 9 9 10 10 11 11 12 12 13 4 8 8 4 4 6 8 J K K L D E F G H I M N O P Q Q Q R S T U V 8 7 8 8 8 7 7 7 W X Y Z 14 14 AA AB AC AD AD AE AF AG AH AI AJ ...

Page 111: ...ttle cables AF Route the radiator fan motor lead over the front wheel sensor lead AG Route the horn lead between the brake hose front brake master cylinder to hydraulic unit and the clutch hose and to the inside of the throttle cables AH Forward AI Face the buckle of the plastic band rearward with the end pointing downward Do not cut off the excess end of the plastic locking tie AJ Fasten the immo...

Page 112: ...CABLE ROUTING 2 51 Fuel tank and throttle bodies left side view A B C D E F G 1 2 3 3 5 3 4 6 ...

Page 113: ... overflow hose and fuel tank breather hose with their white paint marks facing forward Install each hose onto the hose fitting of the fuel tank up to the wide portion at the base of the fitting C Install the cylinder head breather hose with its yellow paint mark facing to the left D Point the ends of the hose clamp to the left E Make sure that the gap between the end of the cylinder head breather ...

Page 114: ...CABLE ROUTING 2 53 Coolant reservoir rear and left side view A A B C 1 1 1 1 2 2 3 2 3 4 4 5 6 6 6 7 N O P P Q 7 8 F D E E G H I J K L M ...

Page 115: ...o the radiator pipe making sure that it contacts the radiator I Route the coolant reservoir hose through the opening in the frame as shown in the illustration and to the inside of the frame J Fasten the coolant reservoir hose to the radiator inlet hose with a plastic locking tie K Connect the end of the coolant reservoir hose that is identified by the white paint mark to the coolant reservoir Inst...

Page 116: ...CABLE ROUTING 2 55 Engine left side view A B C D E F F F G H I J K L M N O 1 1 2 3 4 2 3 4 4 5 5 5 6 7 6 7 6 7 8 8 8 9 13 14 14 15 16 16 17 11 11 10 12 Q Q P ...

Page 117: ...ide of the oil level switch lead and then fit the leads in between the generator cover and the middle gear side cover E Make sure that the stator coil lead is covered completely by the protective sleeve and rubber boot F To electrical components tray G Route the engine ground lead stator coil lead and starter motor lead to the outside of the timing chain tensioner H Fasten the stator coil lead and...

Page 118: ...CABLE ROUTING 2 57 Front brake hose right side view A B 1 2 2 3 4 10 3 5 6 D E C 12 11 7 F G H I J 1 7 8 8 K L M N 5 9 14 15 13 ...

Page 119: ... and starter motor lead over the wire harness and then route the leads outward at the location shown in the illustration F To wire harness G To immobilizer unit H Fasten the immobilizer unit lead to the guide with a plastic locking tie I Forward J Align the white tape on the immobilizer unit lead with the plastic locking tie Face the buckle of the plastic locking tie upward with the end pointing r...

Page 120: ...ray right side view AA A B C D E J F F K L M N 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 20 21 22 23 24 25 26 30 33 20 31 32 34 34 35 36 10 37 37 30 S R O P Q G 14 H I 13 14 T U AB V W X Z 27 28 29 Y AC AD AE AF AG 13 AH 11 12 AI AJ AK AL ...

Page 121: ... the starter relay lead to the outside of the main fuse leads J Install the positive battery lead terminal and negative battery lead terminal to the starter relay so that the terminals are parallel to the relay as shown in the illustration K Route the fuse box 1 lead and fuse box 2 lead to the inside of the wire harness starting circuit cut off relay lead and starter relay lead L Install the grip ...

Page 122: ...ray right side view AA A B C D E J F F K L M N 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 20 21 22 23 24 25 26 30 33 20 31 32 34 34 35 36 10 37 37 30 S R O P Q G 14 H I 13 14 T U AB V W X Z 27 28 29 Y AC AD AE AF AG 13 AH 11 12 AI AJ AK AL ...

Page 123: ...tor coil lead to the inside of the wire harness starting circuit cut off relay lead and starter relay lead AF Route the stator coil lead to the outside of the ECU leads headlight relay lead turn signal hazard relay lead fuse box 1 lead fuse box 2 lead and leads that pass through the rubber cover AG Route the left handlebar switch lead and right handlebar switch lead to the outside of the O2 sensor...

Page 124: ...CABLE ROUTING 2 63 Engine right side view A 1 2 3 4 5 6 3 3 4 5 5 C E F B 6 7 G D ...

Page 125: ...that there is no slack in the crankshaft position sensor lead C Route the rear brake light switch lead to the inside of the frame D Route the rear brake light switch lead to the outside of the frame E Face the buckle of the plastic locking tie outward with the end pointing downward and positioned between the frame and the footrest plate Do not cut off the excess end of the plastic locking tie F Ro...

Page 126: ...CABLE ROUTING 2 65 Rear brake hose right side view A B 1 1 1 2 2 2 3 3 5 4 5 4 5 4 5 4 5 4 5 4 4 5 5 C D E F G K L M H I I J ...

Page 127: ... D Install the brake fluid reservoir hose with its white paint mark facing toward the swingarm E Install the brake fluid reservoir hose onto the hose fitting of the rear brake master cylinder making sure that the hose contacts the master cylinder F To rear wheel sensor G Route the rear wheel sensor lead to the outside of the brake hose hydraulic unit to rear brake caliper at the location shown in ...

Page 128: ...CABLE ROUTING 2 67 Throttle bodies top view A B C D E E 1 2 3 4 5 6 9 9 7 8 9 10 11 12 13 14 F 15 16 17 23 18 19 20 21 22 G H I J ...

Page 129: ...el rail A Route the immobilizer unit lead over the cylinder head breather hose B Route the cylinder 1 left ignition coil lead under the cylinder head breather hose C Route the accelerator position sensor lead under the cylinder head breather hose D Route the cylinder 1 right ignition coil lead under the cylinder head breather hose E Insert the projection on the wire harness holder into the hole in...

Page 130: ...CABLE ROUTING 2 69 Hydraulic unit assembly top view A B C D 2 2 1 2 3 5 5 5 7 8 9 14 15 N M 19 13 F 14 15 16 16 17 17 18 18 L E J G H I 11 13 12 4 6 4 K 10 10 ...

Page 131: ...pler tail brake light coupler lean angle sensor sub wire harness coupler and alarm couplers making sure that the connectors and couplers are covered completely E Slide the rubber cover over the sidestand switch coupler rear brake light switch coupler neutral switch coupler rear wheel sensor coupler and oil level switch coupler making sure that the couplers are covered completely F Route the sidest...

Page 132: ...CABLE ROUTING 2 71 Rear fender top view A B C D E E F G 1 1 2 2 3 4 5 6 H I J 1 2 3 4 6 7 4 3 ...

Page 133: ...Route the tail brake light lead and rear left turn signal light lead to the outside of the rib on the rear fender E Route the tail brake light lead rear left turn signal light lead rear right turn signal light lead and frame ground lead to the outside of the rib on the rear fender F Fasten the lean angle sensor sub wire harness license plate light lead tail brake light lead frame ground lead rear ...

Page 134: ...CABLE ROUTING 2 73 ...

Page 135: ... 3 16 CHECKING THE BRAKE HOSES 3 17 CHECKING THE WHEELS 3 17 CHECKING AND TIGHTENING THE SPOKES 3 17 CHECKING THE TIRES 3 18 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM PIVOT 3 19 LUBRICATING THE SWINGARM PIVOT 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 20 LUBRICATING THE STEERING HEAD 3 21 CHECKING THE FASTENERS 3 21 LUBRICATING THE LEVERS 3 21 LUBRICATING THE PEDALS 3 21 CHECKING...

Page 136: ...AKE LIGHT SWITCH 3 30 CHECKING AND LUBRICATING THE CABLES 3 31 CHECKING THE THROTTLE GRIP OPERATION 3 31 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 REPLACING THE HEADLIGHT BULBS 3 32 REPLACING THE AUXILIARY LIGHT BULBS 3 33 ...

Page 137: ......

Page 138: ...formed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel h...

Page 139: ...t Lubricate with lithium soap based grease 16 Sidestand center stand Check operation Lubricate with lithium soap based grease 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check operation 21 Engine oil Change Check oil...

Page 140: ...clutch service Regularly check and if necessary correct the brake fluid and clutch fluid levels Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged ...

Page 141: ...is routed correctly 4 Install Fuel tank bolts 5 Install Right side panel Left side cowling Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Remove Ignition coil 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any di...

Page 142: ...DIES on page 7 5 Clutch cover Refer to CLUTCH on page 5 52 Cylinder head cover Refer to CAMSHAFTS on page 5 11 2 Measure Valve clearance Out of specification Adjust TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence a Turn the crankshaft clockwise and align the pickup rotor K mark a and crankcase mating surface b At this time c...

Page 143: ...oving the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 4 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 TIP Cover the timing chain opening and spark plug holes with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve...

Page 144: ...s and the valve pad num ber Example 1 48 mm 0 058 in 0 04 mm 0 002 in 1 52 mm 0 060 in The valve pad number is 152 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 available valve pads Example Valve pad number 152 Rounded value 150 New valve pad number 150 f Install the new valve pad 1 and the valve l...

Page 145: ...or installation reverse 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 hose Exhaust system Cylinder head breather hose Checking the throttle body synchronization 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerst...

Page 146: ... the standard Otherwise the engine may run roughly at idle and the throttle bodies may not operate properly TIP Turn the cylinder 1 air screw or cylinder 2 air screw using the carburetor angle driver 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 turn the screw in fully and be sure to synchron...

Page 147: ...DJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume 1 Turn the main switch to OFF 2 Simultaneously press and hold the left set button 1 and right set button 2 turn the main switch to ON and continue to press the buttons for 8 seconds or more TIP All displays on the meter disappear except the odometer displays dIAG appears on th...

Page 148: ...pressing the left set button or right set button TIP The CO adjustment volume appears on the odometer LCD To decrease the CO adjustment volume press the right set button To increase the CO adjustment volume press the left set button 8 Simultaneously press the left set button and right set button to return to the cylinder selec tion step 5 9 Turn the main switch to OFF to cancel the mode EAS21050 C...

Page 149: ... the air filter element will also affect throttle body synchronization leading to poor engine per formance and possible overheating TIP When installing the air filter element into the air filter case cover make sure that the sealing sur faces are aligned to prevent any air leaks 7 Install Fuel tank bolts 8 Install Right side panel Left side cowling Rider seat Refer to GENERAL CHASSIS on page 4 1 E...

Page 150: ...y 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 52 EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed the hydraulic...

Page 151: ... THE FRONT DISC BRAKE 1 Adjust Brake lever position distance a from the throttle grip to the brake lever a While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position TIP Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever WARNING EWA13050 A soft or spongy feeling in the brake lever can indicate the presen...

Page 152: ...elated parts are removed NOTICE ECA23P1037 Bleed the brake system in the following or der 1st step Right front brake caliper 2nd step Left front brake caliper 3rd step Rear brake caliper WARNING EWA23P1011 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any br...

Page 153: ...ng the ABS repeat steps e to i and then fill the brake master cylinder res ervoir or brake fluid reservoir to the proper level with the recommended brake fluid l Tighten the bleed screw to specification m Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 WARNING EWA13110 After bleeding the hydraulic brake system...

Page 154: ...EWA13260 Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always balance the wheel 2 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 23 and CHECKING THE REAR WHEEL on page 4 32 3 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 23 and CHECKING THE REAR WHEEL on page 4 32 EAS21681 CHEC...

Page 155: ...s to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden deflation 1 Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 2...

Page 156: ...Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS23P1108 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearin...

Page 157: ...etely and then tighten it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 92 e Install the rubber washer 3 f Install the ...

Page 158: ...int and metal to metal moving parts of the centerstand EAS23P1075 CHECKING THE SIDESTAND SWITCH Refer to CHECKING THE SWITCHES on page 8 137 EAS21531 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 falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and out...

Page 159: ...um adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 8 Standard 5 5 Maximum 0 1 a b 2 Current setting Direction a Rebound damping is increased sus pension is harder Direction b Rebound dam...

Page 160: ... Repair Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 96 EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload 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 b Align the appropriate mark on t...

Page 161: ...a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled 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 10 click s o...

Page 162: ...everal min utes and then turn it off 2 Place a container under the engine oil drain bolts 3 Remove Engine oil filler cap 1 along with the O ring 4 Remove Engine oil drain bolt oil tank 1 along with the gasket 2 Engine oil drain bolt crankcase 3 along with the gasket 4 5 Drain Engine oil completely from the oil tank and crankcase 6 If the oil filter cartridge is also to be replaced perform the foll...

Page 163: ...13 Check Engine oil pressure Refer to MEASURING THE ENGINE OIL PRESSURE on page 3 26 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the...

Page 164: ... if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 5 2 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Radiator...

Page 165: ...n the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove Coolant drain bolt water pump 1 along with the copper washer 2 4 Drain Coolant from the engine and radiator 5 Remove Coolant reservoir 1 Coolant reservoir cap 2 6 Drain Coolant from the c...

Page 166: ...k a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 27 TIP Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Left side cowling Refer to GENERAL CHASSIS on page 4 1 EAS21460 CHECKING THE FINAL GEAR OIL LEVEL 1 Stand the vehicle on a ...

Page 167: ...tion Rear brake light switch operation When operating the brake lever and brake pedal confirm that the brake light turns on Faulty Refer to CHECKING THE SWITCHES on page 8 137 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the brakin...

Page 168: ... grip movement Rough movement Lubricate or replace the defective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right 3 Check Throttle cable free play a Out of specification Adjust 4 Adjust Throttle cable free pl...

Page 169: ... on page 8 140 EAS21810 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically a Turn the adjusting screws 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screws 1 in direction a or b EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove Headlight bulb cover 1 2 Disconnect Headlight coupler 1 3 Detac...

Page 170: ...e luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Attach Headlight bulb holder 7 Connect Headlight coupler 8 Install Headlight bulb cover EAS23P1076 REPLACING THE AUXILIARY LIGHT BULBS The following procedure applies to both of the auxiliary light bulbs 1 Remove Headlight assembly Refer to GENER...

Page 171: ...ALLING THE FRONT WHEEL FRONT BRAKE DISCS 4 27 REAR WHEEL 4 29 REMOVING THE REAR WHEEL 4 32 DISASSEMBLING THE REAR WHEEL 4 32 CHECKING THE REAR WHEEL 4 32 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 33 ASSEMBLING THE REAR WHEEL 4 33 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 34 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 34 FRONT BRAKE 4 36 INTRODUCTION 4 44 CHECKING THE FRONT BRAKE DISC...

Page 172: ...HE BRAKE PIPES 4 70 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 70 HYDRAULIC UNIT OPERATION TESTS 4 71 TRIAL RUN 4 75 HANDLEBAR 4 76 REMOVING THE HANDLEBAR 4 79 CHECKING THE HANDLEBAR 4 79 INSTALLING THE HANDLEBAR 4 79 FRONT FORK 4 82 REMOVING THE FRONT FORK LEGS 4 85 DISASSEMBLING THE FRONT FORK LEGS 4 85 CHECKING THE FRONT FORK LEGS 4 86 ASSEMBLING THE FRONT FORK LEGS 4 87 INSTALLING THE FRONT FORK...

Page 173: ...NAL GEAR BACKLASH 4 109 ADJUSTING THE FINAL GEAR BACKLASH 4 110 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 111 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 111 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 112 REMOVING AND INSTALLING THE BEARINGS 4 113 ASSEMBLING THE FINAL DRIVE ASSEMBLY 4 114 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 114 CHECKING THE DRIVE SHAFT 4 117 INSTAL...

Page 174: ... carrier bracket 1 7 Left grab bar 1 8 Right grab bar 1 9 Additional carrier 1 10 Seat bracket 1 For installation reverse the removal proce dure 8 6 2 1 4 3 7 4 5 9 10 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 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 R 7 Nm 0 7 m kgf 5 1...

Page 175: ...t into the seat holder d in the seat brack et and then push the front of the seat down to lock it in place To install the rider seat in the low position a Install the rider seat height position adjuster so that the match mark a on the adjuster is aligned with the L mark b on the seat bracket b Insert the projection c on the rear of the rider seat into the seat holder d in the seat brack et and the...

Page 176: ... TIP Before tightening the bolts make sure to align the bolt holes a in the additional carrier with the bolt holes b in the seat bracket 4 Install Grab bars 1 Washers 2 Standard carrier bracket Standard carrier Passenger seat 1 2 a 2 a 2 1 3 3 T R Seat bracket bolt 7 Nm 0 7 m kgf 5 1 ft lbf Additional carrier bolt 7 Nm 0 7 m kgf 5 1 ft lbf 3 Spring nut T R Grab bar bolt 32 Nm 3 2 m kgf 23 ft lbf S...

Page 177: ...asher with the projec tions b on the grab bar 5 Remove Rubber plug 1 6 Install Standard carrier 1 TIP Use the two standard carrier bracket bolts 2 and the standard carrier bolt 45 mm 3 T R Standard carrier bolt 20 Nm 2 0 m kgf 14 ft lbf 1 2 a b 1 3 1 2 ...

Page 178: ...connect 3 License plate light coupler 1 Disconnect 4 Tail brake light coupler 1 Disconnect 5 Tail brake light assembly 1 6 Lean angle sensor coupler 1 Disconnect 7 Lean angle sensor 1 8 Frame ground lead 1 9 Lean angle sensor sub wire harness coupler 1 Disconnect 10 Lean angle sensor sub wire harness 1 1 2 3 9 10 6 8 7 4 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf...

Page 179: ...1 Seat lock cable 1 12 Seat lock bracket 1 13 Seat lock 1 For installation reverse the removal proce dure 11 12 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 15 Nm 1 5 m kgf 11 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R ...

Page 180: ...tic locking tie 1 TIP Fold the ABS test coupler lead 2 and then fasten the ABS test coupler lead lean angle sensor sub wire harness rear turn signal light leads tail brake light lead and license plate light lead with the plastic locking tie Position the plastic locking tie 40 60 mm 1 57 2 36 in a from the edge of the holder 3 Install ABS unit cover 1 TIP Insert the projections a on the ABS unit co...

Page 181: ...e cowling 1 2 Right side cowling 1 3 Right side panel 1 4 Engine guard 1 For installation reverse the removal proce dure 2 3 1 4 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R ...

Page 182: ...SIDE COWLINGS 1 Install Left side cowling 1 a Insert the projections a on the left side cowl ing into the grommets b b Install the left side cowling bolts and quick fastener screws and then tighten the bolts to specification 2 Install Right side cowling 1 a Insert the projection a on the right side cowl ing into the grommet b and insert the projec tions c on the cowling into the slots d b Tighten ...

Page 183: ...de panel and engine guard 1 Negative battery lead 1 Disconnect 2 Positive battery lead 1 Disconnect 3 Battery 1 4 Battery seat 1 5 Owner s tool kit 1 6 Starting circuit cut off relay 1 7 Starter relay coupler 1 Disconnect 8 Starter relay 1 9 Main fuse 1 10 Joint coupler 2 Disconnect 11 Headlight relay 1 10 9 1 2 7 11 8 6 3 4 5 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R ...

Page 184: ... components tray 1 2 Order Job Parts to remove Q ty Remarks 12 Turn signal hazard relay 1 13 Radiator fan motor relay 1 14 Stator coil coupler 1 Disconnect For installation reverse the removal proce dure 13 14 12 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R ...

Page 185: ...t 5 Left handlebar switch coupler 1 Disconnect 6 O2 sensor 1 coupler 1 Disconnect 7 O2 sensor 2 coupler 1 Disconnect 8 Main switch coupler 2 Disconnect 9 Negative battery coupler 1 Disconnect 10 Crankshaft position sensor coupler 1 Disconnect 11 ECU coupler 2 Disconnect 12 Electrical components tray 1 2 3 1 3 9 10 4 7 6 5 8 12 11 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 ...

Page 186: ...s to remove Q ty Remarks 13 Rectifier regulator 1 14 Rectifier regulator bracket 1 15 ECU bracket 1 16 ECU engine control unit 1 For installation reverse the removal proce dure 13 14 3 15 16 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 ...

Page 187: ...e electrical components tray bolts 2 and 3 temporarily b Tighten electrical components tray bolts 3 c Tighten electrical components tray bolt 2 d Tighten electrical components tray bolt 4 T R Electrical components tray bolt 2 7 Nm 0 7 m kgf 5 1 ft lbf Electrical components tray bolt 3 and 4 10 Nm 1 0 m kgf 7 2 ft lbf 3 2 1 4 ...

Page 188: ...indshield bracket 1 3 Windshield 1 4 Meter assembly cover 1 5 Headlight cover 1 6 Headlight sub wire harness coupler 1 Disconnect 7 Headlight assembly 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 For installation reverse the removal proce dure 6 1 3 2 4 4 5 8 9 4 7 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 0 5 Nm 0 05 m kgf 0 36 ft Ibf T R 0 7 Nm 0 07 m kgf 0 51...

Page 189: ...Remarks 1 Auxiliary light socket 2 2 Auxiliary light bulb 2 3 Headlight bulb cover 2 4 Headlight coupler 2 Disconnect 5 Headlight solenoid coupler 2 Disconnect 6 Headlight bulb 2 7 Headlight sub wire harness 1 For assembly reverse the disassembly pro cedure 7 1 1 2 2 6 6 3 4 4 5 5 ...

Page 190: ...b wire harness coupler TIP Make sure that the headlight sub wire harness is routed properly Refer to CABLE ROUTING on page 2 43 3 Install Windshield 1 Windshield brackets 2 TIP Install the windshield in the position shown in the illustration Install the windshield bracket with the L mark on the left side of the windshield and the wind shield bracket with the R mark on the right side Point the arro...

Page 191: ...r case cover 1 2 Air filter element 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Cylinder head breather hose 1 Disconnect 5 Air filter case joint clamp screw 2 Loosen 6 Air filter case 1 7 Air chamber 1 For installation reverse the removal proce dure 1 9 2 3 4 5 5 6 7 New New 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0 28 m...

Page 192: ...TER CASE 1 Remove Fuel tank bolts 1 Air filter case TIP After removing the fuel tank bolts lift up the front of the fuel tank NOTICE ECA23P1003 When lifting up the fuel tank be careful not to pull the fuel tank overflow hose and fuel tank breather hose 1 ...

Page 193: ...1 5 Front wheel sensor lead guide 1 For Europe 6 Front reflector 2 For Oceania 7 Front brake caliper 2 8 Front wheel axle pinch bolt 2 Loosen 9 Front wheel axle 1 10 Front wheel 1 11 Collar right side 1 5 6 4 2 7 1 7 6 8 9 5 5 11 10 3 LS New LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 72 Nm 7 2 m kgf 52 ft Ibf T R 7 ...

Page 194: ...1 14 Front brake disc 2 For installation reverse the removal proce dure 5 5 14 14 13 12 LS New LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 72 Nm 7 2 m kgf 52 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R ...

Page 195: ... wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Front wheel sensor rotor 1 3 Oil seal 1 4 Wheel bearing 2 5 Spacer 1 For assembly reverse the disassembly pro cedure 2 5 3 4 5 4 1 New New New LS LS LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 196: ...he front wheel is elevated EAS21910 DISASSEMBLING THE FRONT WHEEL NOTICE ECA23P1005 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 outside of the front wheel hub b R...

Page 197: ...ey have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled 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 Front wheel senso...

Page 198: ...L NOTICE ECA23P1008 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 Install Wheel bearings a Install the new wheel bearing left side NOTICE ECA23P1009 Do not contact the wheel bearing inner race 1 or balls 2 Co...

Page 199: ...e front wheel on a suitable balancing stand a Spin the front wheel 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 ...

Page 200: ...Front brake discs TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 44 3 Lubricate Oil seal lips 4 Install Collars Front wheel sensor housing Front wheel TIP Align the slot a in the front wheel sensor hous ing with the projection b of the front fork before assembly 5 Install Front wheel axle Front whee...

Page 201: ... lead holder Front wheel sensor Front brake hose holder TIP When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials NOTICE ECA23P1012 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 pa...

Page 202: ...holder 2 3 Rear wheel sensor 1 4 Rear wheel axle pinch bolt 1 Loosen 5 Rear wheel axle nut 1 6 Brake torque rod 1 7 Rear wheel axle 1 8 Rear brake caliper 1 9 Rear wheel 1 10 Rear wheel sensor housing 1 11 Collar 1 1 9 11 10 5 6 8 3 7 6 4 2 2 LS New 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 23 Nm 2 3 m kgf 17 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T...

Page 203: ... Remarks 12 Rear brake disc cover 1 13 Rear brake disc 1 For installation reverse the removal proce dure 13 12 6 LS New 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 23 Nm 2 3 m kgf 17 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R ...

Page 204: ...al 1 2 Rear wheel drive hub 1 3 Wheel bearing 1 4 Collar 1 5 Rear wheel drive hub damper 6 6 Bearing 1 7 Spacer 1 8 Rear wheel sensor rotor 1 9 Oil seal 1 10 Wheel bearing 1 For assembly reverse the disassembly pro cedure 1 3 2 4 5 6 10 8 5 9 7 New New New LS 8 Nm 0 8 m kgf 5 8 ft Ibf T R LS LT ...

Page 205: ... sure to remove the rear wheel sensor before removing the rear wheel sensor housing otherwise the sensor could be damaged TIP Move the rear wheel to the right to separate it from the final drive assembly EAS22080 DISASSEMBLING THE REAR WHEEL NOTICE ECA23P1015 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor ...

Page 206: ...sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 24 3 Measure Wheel sensor rotor deflection Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 24 EAS22140 ASSEMBLING THE REAR WHEEL NOTICE ECA23P1018 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor ...

Page 207: ...R WHEEL REAR BRAKE DISC 1 Install Rear brake disc Rear brake disc cover TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 59 3 Lubricate Oil seal lips 4 Install Rear wheel sensor housing Rear wheel Rear brake caliper Rear wheel axle Brake torque rod Rear wheel axle nut TIP Align the slot a of the rear whee...

Page 208: ...e the rear wheel sensor lead refer to CABLE ROUTING on page 2 43 TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 8 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly T R Brake torque rod bolt 30 Nm 3 0 m kgf 22 ft lbf Rear wheel axle nut 125 Nm 12 5 m kgf 90 ft lbf Rear wh...

Page 209: ...n 1 3 Brake pad spring 1 4 Front brake pad 2 5 Front brake hose holder 1 Left side only 6 Front reflector 1 For Oceania 7 Front wheel sensor lead guide 1 For Europe Left side only 8 Front wheel sensor lead holder 1 Left side only 9 Front brake caliper 1 10 Bleed screw 1 Left brake caliper side New 4 3 1 2 9 10 8 6 7 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 40 Nm 4 0 m kgf 29 f...

Page 210: ... brake pads Order Job Parts to remove Q ty Remarks 11 Bleed screw 1 Right brake caliper side For installation reverse the removal proce dure New 11 7 Nm 0 7 m kgf 5 1 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 211: ...cap 1 6 Brake master cylinder reservoir diaphragm hold er 1 7 Brake master cylinder reservoir diaphragm 1 8 Lower hand shield bracket 1 9 Brake lever 1 8 1 2 3 4 9 7 6 5 S LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R ...

Page 212: ...draulic unit 1 15 Front brake master cylinder holder 1 16 Front brake master cylinder 1 For installation reverse the removal proce dure 13 16 12 14 11 15 10 New S LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 6 Nm 0 6 ...

Page 213: ...4 40 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 2 BF S New BF 1 ...

Page 214: ...ge 3 15 1 Front brake hose holder 1 Left side only 2 Brake hose union bolt 1 3 Brake hose gasket 1 Left side only 4 Brake hose left front brake caliper to right front brake caliper 1 Left brake caliper side 5 Brake hose gasket 2 6 Brake hose left front brake caliper to right front brake caliper 1 Right brake caliper side New New 6 1 4 5 3 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T...

Page 215: ...l iper 1 Left side only 8 Front reflector 1 For Oceania 9 Front wheel sensor lead guide 1 For Europe Left side only 10 Front wheel sensor lead holder 1 Left side only 11 Front brake caliper 1 For installation reverse the removal proce dure 8 9 11 7 10 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 216: ... 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side For assembly reverse the disassembly pro cedure S S S S BF BF BF BF 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R New 2 7 New 6 6 5 5 6 6 7 New New New New New 1 4 3 8 9 ...

Page 217: ...emove Front wheel Refer to FRONT WHEEL on page 4 20 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front ...

Page 218: ...ose or disassem ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring TIP Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed s...

Page 219: ... FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Brake hose gaskets Brake hose left front brake caliper to right front brake caliper Brake hose hydraulic unit to left front brake caliper TIP Put the end of the brake hose into a container and pum...

Page 220: ... 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 EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22411 ASSEMBLING THE FRONT BRAKE CALIPERS WARNING EWA13621 Before installation all internal brake com p...

Page 221: ...e 2 onto the brake caliper make sure that the projection c on the brake hose 2 contacts the pro jection d on the brake hose 1 Right side When installing the brake hose 2 onto the brake caliper make sure that the paint mark e on the brake hose 2 faces outward and that the brake pipe f contacts the pro jection g on the brake caliper 2 Remove Front brake caliper 3 Install Brake pads Brake pad spring ...

Page 222: ...490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose front brake master cylinder to hydraulic unit 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE F...

Page 223: ...cessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leadi...

Page 224: ...FRONT BRAKE 4 51 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 a ...

Page 225: ...er Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad shim 2 5 Brake pad support 2 For installation reverse the removal proce dure S S 27 Nm 2 7 m kgf 20 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 2 5 4 1 5 3 ...

Page 226: ...nion bolt 1 2 Brake hose gasket 2 3 Brake hose rear brake master cylinder to hy draulic unit 1 4 Footrest plate 1 5 Brake fluid reservoir cap 1 6 Brake fluid reservoir diaphragm holder 1 7 Brake fluid reservoir diaphragm 1 8 Brake fluid reservoir 1 9 Brake fluid reservoir hose 1 New New 2 6 5 7 9 3 4 8 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T ...

Page 227: ... 10 Rear brake master cylinder 1 11 Rear brake light switch coupler 1 Disconnect 12 Rear brake light switch 1 For installation reverse the removal proce dure New 10 11 12 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 228: ...ove Q ty Remarks 1 Rear brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Circlip 1 4 Brake hose joint 1 5 Filter plate 1 6 Filter 1 7 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S New New New New BF 3 4 5 6 7 2 1 17 Nm 1 7 m kgf 12 ft Ibf ...

Page 229: ...t 2 3 Brake hose hydraulic unit to rear brake caliper 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad shim 2 8 Brake pad support 2 9 Rear wheel axle pinch bolt 1 Loosen 10 Rear wheel axle 1 S S S New 125 Nm 12 5 m kgf 90 ft lbf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 9 1 2 5 3 8 ...

Page 230: ... to remove Q ty Remarks 11 Rear brake caliper bracket 1 For installation reverse the removal proce dure S S S 125 Nm 12 5 m kgf 90 ft lbf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 11 ...

Page 231: ...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 6 Nm 0 6 m kgf 4 3 ft Ibf T R New New BF S 1 2 3 4 ...

Page 232: ...c Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 44 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 44 5 Adjust Brake disc deflection Re...

Page 233: ... fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose ga...

Page 234: ...e caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket Cracks damage Replace EAS22651 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA23P1006 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the b...

Page 235: ... a is installed between the projections b on the brake caliper 5 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids ma...

Page 236: ...ake hose rear brake master cylinder to hy draulic unit 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS23P1070 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove Adjuster rod pin 1 Rear brake master cylinder joint 2 TIP Remove the adjuster rod pin and then remove the rear brake master cylinder joint EAS22720 CHECKING THE RE...

Page 237: ... The rear brake light switch installation length a should be 3 8 4 8 mm 0 15 0 19 in Install the rear brake light switch spring 2 as shown in the illustration 2 Install Brake hose gaskets Brake hose rear brake master cylinder to hy draulic unit 1 Brake hose union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 43 NOT...

Page 238: ...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 15 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE ...

Page 239: ...SSIS on page 4 1 Rear brake fluid reservoir Refer to REAR BRAKE on page 4 52 Fuel tank bracket Refer to FUEL TANK on page 7 1 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt Gasket 1 2 3 Brake hose front brake master cylinder to hy draulic unit brake pipe joint 1 Disconnect 4 Brake hose union bolt Gasket 1 2 1 2 2 3 4 4 New New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf...

Page 240: ...ulic unit brake pipe joint to rear brake caliper 1 Disconnect 8 Brake hose union bolt Gasket 1 2 9 Brake hose rear brake master cylinder to hy draulic unit brake pipe joint 1 Disconnect 10 Rear fender assembly 1 11 Rear mudguard 1 For installation reverse the removal proce dure 8 9 7 6 10 11 5 6 New New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 241: ...ake pipe joint 1 2 Hydraulic unit brake pipe 4 3 Hydraulic unit assembly 1 4 Rear fender 1 For installation reverse the removal proce dure 1 2 2 4 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R ...

Page 242: ...removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler push the lock lever down to release the lock NOTICE ECA23P1053 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hoses Brake pipes TIP Do not operate the brake lever and brake pedal while removing the brake hoses a...

Page 243: ...ts M10 1 00 installed in the flare nut holes before installing the hydraulic unit assem bly a Remove the rubber plugs or bolts M10 1 00 b Assemble the hydraulic unit assembly hy draulic unit brake pipes and hydraulic unit brake pipe joint TIP Temporarily tighten the brake pipe flare nuts 2 Install Hydraulic unit assembly Hydraulic unit brake pipe joint to the rear fender 3 Tighten Hydraulic unit b...

Page 244: ...r does not enter the brake master cylinder reser voir or brake fluid reservoir Water will sig nificantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 8 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 9 Check ...

Page 245: ... warning light comes on and the ABS does not operate 5 Remove the protective cap and then connect the test coupler adapter 1 to the ABS test coupler 2 6 Set the main switch to ON while operating the brake lever and the brake pedal simulta neously TIP Do not push the start switch when setting the main switch to ON otherwise the operation test will not begin 7 Check Hydraulic unit operation When the...

Page 246: ...no danger of it falling over 1 Place the vehicle on the centerstand 2 Set the main switch to OFF 3 Remove Rider seat Right side cowling Refer to GENERAL CHASSIS on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic unit operation test 2 If the battery voltage is lower than 10...

Page 247: ...s for approxi mately 2 5 seconds TIP The reaction force pulsating action consists of quick pulses NOTICE ECA23P1032 Check that the pulsating action is felt in the brake lever brake pedal and again in the brake lever in this order If the pulsating action is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydrauli...

Page 248: ...ABS Anti Lock Brake System 4 75 EAS22820 TRIAL RUN After all checks and servicing are completed al ways ensure the vehicle has no problems by performing a trial run at a speed of faster than 30 km h ...

Page 249: ...h 1 7 Clutch master cylinder holder 1 8 Clutch master cylinder assembly 1 9 Left handlebar switch 1 10 Handlebar grip 1 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 17 Nm 1 7 m kgf 12 ft I...

Page 250: ...cylinder assembly 1 19 Right handlebar switch 1 20 Throttle cable housing 2 21 Throttle cable 2 Disconnect 22 Throttle grip 1 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 17 Nm 1 7 m kgf 1...

Page 251: ...3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 23 23 24 LS LS LT LT ...

Page 252: ...vehicle so that there is no danger of it falling over 2 Install Handlebar 1 Upper handlebar holders 2 NOTICE ECA23P1061 First tighten the bolts on the front side of the handlebar holder and then on the rear side TIP The upper handlebar holders should be in stalled with the punch marks a facing for ward Align the punch mark b on the handlebar with the upper surface of the lower handlebar hold er 3 ...

Page 253: ... grip 3 and the grip end 7 Install Left handlebar switch 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 8 Install Clutch master cylinder assembly 1 Clutch master cylinder holder 2 TIP The clutch master cylinder holder should be in stalled with the punch mark a forward T R Right handlebar switch screw 3 5 Nm 0 35 m kgf 2 5 ft lbf T R Front brake master cy...

Page 254: ... grip is 11 13 mm 0 43 0 51 in c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried d Install the left grip end and left hand shield TIP There should be 1 3 mm 0 04 0 12 in of clear ance b between the handlebar grip and the grip end 10 Adjust Throttle cable free play Refer to CHECKING THE THROTTLE GRIP OP...

Page 255: ...FRONT WHEEL on page 4 20 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure 1 5 4 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 20 Nm 2 0 m kgf 14 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 ...

Page 256: ...plies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Damper adjusting rod 1 4 Nut 1 5 Collar 1 6 Washer 1 7 Spacer 1 8 Fork spring 1 9 Fork spring guide 1 10 Damper rod assembly bolt 1 11 Copper washer 1 10 11 1 2 3 4 5 6 7 8 9 New New LT LT 15 Nm 1 5 m kgf 11 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R LS LS ...

Page 257: ...ly 1 13 Dust seal 1 14 Oil seal clip 1 15 Outer tube 1 16 Oil seal 1 17 Washer 1 18 Outer tube bushing 1 19 Inner tube bushing 1 20 Inner tube 1 For assembly reverse the disassembly pro cedure 20 12 15 18 17 16 14 13 New New New New New LT LT 15 Nm 1 5 m kgf 11 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 19 LS LS ...

Page 258: ...THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Nut 4 Collar 5 a Press down on the spacer with the fork spring compressor 6 and then secure the com pressor with a suitable tool 7 b Hold the spring preload adjusting bolt 8 and loosen the nut 4 c Remove the cap bolt d Remove the fork spring compress...

Page 259: ...s must be replaced EAS23011 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner 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 Fork spring free length a Out of specification Replace 3 Check Damper rod assembly Damage wear Replace Obstruct...

Page 260: ...l seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Lubricate Inner tube s outer surface 2 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOTICE ECA23P1034 Make sure to face the numbered side of the oil seal toward the bottom end of the inner tube TIP Before installing the oil seal lubricate its...

Page 261: ... the inner tube until it contacts the bottom of the inner tube Be careful not to damage the inner tube 9 Tighten Damper rod assembly bolt 1 TIP While holding the damper rod assembly with the damper rod holder 2 tighten the damper rod assembly bolt Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 ...

Page 262: ...the damper rod slowly be cause the fork oil may spurt out 14 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 15 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring and fork spring guide Out of sp...

Page 263: ...he fork spring TIP Install the spring with the smaller pitch b facing up B f Install the spacer 3 and washer 5 g Press down on the spacer with the fork spring compressor 9 and then secure the com pressor with a suitable tool 10 h Remove the rod puller and the rod puller at tachment i Position the nut 7 as specified c j Set the cap bolt distance d to specification 1 2 3 4 5 6 7 8 a A Fork spring co...

Page 264: ...e front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FR...

Page 265: ... 1 Brake hose holder 1 2 Horn connector 2 Disconnect 3 Horn 1 4 Main switch coupler 2 Disconnect 5 Immobilizer unit coupler 1 Disconnect 6 Steering stem nut cap 1 7 Steering stem nut 1 8 Upper bracket 1 5 4 8 1 3 2 6 7 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf T R 130 Nm 13 m kgf 94 ft lbf T R 20 Nm 2 0 m kgf 14 ft Ibf T...

Page 266: ...1 16 Washer 1 17 Upper bearing 1 18 Lower bearing 1 19 Upper bearing outer race 1 20 Lower bearing outer race 1 For installation reverse the removal proce dure 9 10 11 12 15 16 17 19 20 18 14 13 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft lbf T R 130 Nm 13 m kgf 94 ft lbf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 26 Nm 2 6 m kgf 19 ft...

Page 267: ...ings Bearing 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 new bearing races 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 4 Check Upper bracket...

Page 268: ... TIP Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 82 TIP Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut 7 Install Steering stem nut cap 1 TIP Be sure to fit the hexagonal portion of the steer ing stem nut 2 into the hexagonal recess in the steering stem nut cap and push the cap down until it contacts the ...

Page 269: ...ber assembly lower nut wash er bolt 1 1 1 3 Connecting arm nut washer bolt 2 2 2 4 Connecting arm 2 5 Rear shock absorber assembly upper nut wash er bolt 1 1 1 6 Rear shock absorber assembly 1 7 Relay arm nut washer bolt 1 1 1 8 Relay arm 1 9 Spacer 2 l 79 mm 3 11 in 7 5 1 5 7 3 2 2 4 9 8 3 9 4 3 6 LS LS LS LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 49 Nm 4 9 m kgf 35 ft Ibf...

Page 270: ...7 mm 1 06 in 13 Oil seal 2 D 24 mm 0 94 in 14 Bearing 6 D 27 mm 1 06 in 15 Bearing 1 D 24 mm 0 94 in For installation reverse the removal proce dure 13 12 13 12 14 14 14 14 10 11 14 12 12 12 14 15 LS New New New New New New LS LS LS LS New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 49 Nm 4 9 m kgf 35 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R ...

Page 271: ... 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 50 55 mm 1 97 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 the v...

Page 272: ...seals 3 to the relay arm or swingarm face the paint mark of the oil seals outside When installing the oil seals 4 to the relay arm face the character stamp of the oil seals outside EAS23311 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP When installing the rear shock absorber assem bly lift up the swingarm Recommended lubricant Lithium soap based grease Inst...

Page 273: ... on page 4 96 Final drive assembly Refer to SHAFT DRIVE on page 4 104 Footrest plate Refer to REAR BRAKE on page 4 52 Muffler Refer to ENGINE REMOVAL on page 5 3 1 Rubber boot cover 1 2 Pivot shaft end plate 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Swingarm 1 4 5 1 2 3 LT LS LS LS LT 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 120 Nm 12 m kgf 87 ft ...

Page 274: ... on vehicles that have the XX marks a shown in the de tailed view 8 Rubber boot joint 1 9 Dust cover 2 10 Spacer 1 11 Bearing 2 For installation reverse the removal proce dure 6 8 7 9 11 11 9 10 a LT LS LS LS LT 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 120 Nm 12 m kgf 87 ft lbf T R ...

Page 275: ...ng check the spacer bear ings plate and dust covers 3 Remove Pivot shaft end plate 1 Pivot shaft nut Pivot shaft Swingarm NOTICE ECA23P1064 Before loosening the pivot shaft be sure to remove the pivot shaft end plate TIP Slide the rubber boot 2 toward the swingarm and then remove the pivot shaft end plate EAS23361 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot sha...

Page 276: ... Install Rubber boot 1 TIP Align the mark a on the rubber boot with the mark b on the middle driven pinion gear bearing housing 2 Be sure to fit the lips c on the ends of the rub ber boot into the grooves d in the middle driv en pinion gear bearing housing 2 and rubber boot joint 3 a a 1 a b d 2 1 c d 3 1 c ...

Page 277: ... CHANGING THE FINAL GEAR OIL on page 3 30 Rear wheel Refer to REAR WHEEL on page 4 29 1 Collar 1 2 Final drive assembly 1 3 Drive shaft assembly 1 4 Spring 1 5 Circlip 2 6 Washer 1 7 Oil seal 1 8 Drive shaft 1 For installation reverse the removal proce dure 1 3 New New New New 5 6 7 8 4 2 4 23 Nm 2 3 m kgf 17 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R LS LS M ...

Page 278: ...m Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 110 and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 114 6 Ring gear 1 7 Thrust washer 1 Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 110 and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 114 6 4 1 4 3 2 5 6 7 New New New New New New LT LT LT LT LS LS LS LS LS 40 Nm 4 0 m kgf 29 ft Ibf T R 23 Nm 2 3 m kgf...

Page 279: ... drive pinion gear 1 15 Bearing 1 16 Final drive pinion gear shim Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 114 17 Bearing holder 1 18 Dowel pin 1 19 Final drive pinion gear bearing 1 6 4 8 17 18 9 10 11 13 12 15 16 14 19 New New New New New LT LT LT LT LS LS LS LS LS 40 Nm 4 0 m kgf 29 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 130 Nm 13 m k...

Page 280: ...g gear bearing 1 21 Oil seal 1 22 Collar 1 23 Final gear case 1 For assembly reverse the disassembly pro cedure 6 4 20 21 22 23 New New New New New LT LT LT LT LS LS LS LS LS 40 Nm 4 0 m kgf 29 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 130 Nm 13 m kgf 94 ft lbf T R 150 Nm 15 m kgf 108 ft lbf 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 ...

Page 281: ...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 ex ist check the following points YES NO Symptom Possible cause 1 A pr...

Page 282: ...ew or fairly new 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 1 Secure the final drive assembly in a vise 2 Remove Final gear oil drain bolt 3 Drain Final gear oil from the final drive assembly 4 Measure Final ge...

Page 283: ...ings are over specification adjust the final gear backlash EAS23591 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts M10 1 Ring gear bearing housing bolts M8 2 TIP Working in a crisscross pattern loosen each bolt 1 4 of a turn After all of the bolts are fully loos ened remove them 2 Remove Ring gear bearing housing 1 Ring gear 2 Ring gear shim s 3 Thrust washer 4 3 Adjust...

Page 284: ...r bearing housing along with the ring gear Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 110 2 Measure Ring gear to stopper bolt clearance a Out of specification Adjust 3 Install Ring gear bearing housing along with the ring gear EAS23610 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove Ring gear 1 Stopper bolt 2 Stopper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper b...

Page 285: ...ing in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos ened remove them and the bolts 2 Straighten Punched portion a of the coupling gear nut 1 3 Remove Coupling gear nut Washer Coupling gear 1 with the coupling gear holding tool 2 4 Remove Bearing retainer with the bearing retainer wrench 1 NOTICE ECA14330 The bearing retainer has left hand threads To loose...

Page 286: ... THE BEARINGS 1 Check Bearings Damage Replace 2 Remove Collar 1 Oil seal 2 Bearing 3 with an appropriate press tool 4 and an ap propriate support for the final drive housing 3 Remove Bearing holder 1 Dowel pin 2 Bearing 3 a Heat the final gear case to approximately 150 C 302 F b Remove the inner race from the final drive pinion gear TIP The removal of the final drive pinion gear bear ing is a diff...

Page 287: ...of the final drive case stud bolts Install the final drive case stud bolts so that the specified installed length a is obtained EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR TIP Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced Final gear case Ring gear bearing housing Any bearing 1 Select Final drive pinion gear shim s 1 Rin...

Page 288: ... added to 52 d a numeral indicated by the punch mark on the ring gear bearing housing to be divided by 100 and added to 1 e a numeral positive or negative on the in side of the ring gear to be divided by 100 and added to 38 50 f the bearing thickness constant Example If the final drive housing is marked 97 the ring gear bearing housing is marked 03 the ring gear is marked 08 and f is 13 00 Round o...

Page 289: ...bearing retainer turn it coun terclockwise 3 Install Coupling gear 1 Washer 2 TIP Install the washer with its OUT mark a facing outward 4 Install Coupling gear nut with the coupling gear holding tool 1 5 Stake the coupling gear nut 1 at a cutout a in the final drive pinion gear 6 Install Oil seal 1 Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Ring gear shims Thickness mm 0 25 0 30 0 40 0 50 ...

Page 290: ...Plasti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bear ing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the fol lowing chart i Repeat the measurement steps until the ring gear to thrust washer clearan...

Page 291: ... Tighten Final drive assembly nuts 8 Install Rear wheel Refer to REAR WHEEL on page 4 29 9 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 29 Recommended lubricant Molybdenum disulfide grease Recommended lubricant Lithium soap based grease Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachment ø30 90890 01400 Fork seal driver weight ...

Page 292: ...SHAFT DRIVE 4 119 ...

Page 293: ...HE TIMING CHAIN GUIDE EXHAUST SIDE 5 27 CHECKING THE CYLINDER HEAD 5 27 INSTALLING THE CYLINDER HEAD 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 CYLINDER AND PISTONS 5 37 REMOVING THE PISTONS 5 38 CHECKING THE CYLINDERS A...

Page 294: ...ASSEMBLING THE CLUTCH MASTER CYLINDER 5 65 INSTALLING THE CLUTCH MASTER CYLINDER 5 65 REMOVING THE CLUTCH RELEASE CYLINDER 5 66 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 67 INSTALLING THE CLUTCH RELEASE CYLINDER 5 67 PICKUP ROTOR 5 69 REMOVING THE PICKUP ROTOR 5 70 INSTALLING THE PICKUP ROTOR 5 70 SHIFT SHAFT 5 72 CHECKING THE SHIFT SHAFT 5 74 CHECKING THE STOPPER LEVER 5 74 INSTALLING THE SHIFT SH...

Page 295: ...MISSION 5 103 REMOVING THE TRANSMISSION 5 109 CHECKING THE SHIFT FORKS 5 109 CHECKING THE SHIFT DRUM ASSEMBLY 5 109 CHECKING THE TRANSMISSION 5 109 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 110 INSTALLING THE TRANSMISSION 5 111 MIDDLE GEAR 5 113 REMOVING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 5 117 DISASSEMBLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 5 117 REMOVING THE MIDDLE DRIVE PINION GEAR ASS...

Page 296: ...ression pressure Out of specification Refer to steps c and d a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compr...

Page 297: ...SIS on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Pistons valves cylin der head gasket or piston ring s possi bly defective Re pair T R Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf T R Ignition coil bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE ...

Page 298: ...t pipe joint bolt 1 5 Rubber cover 1 6 Muffler 1 7 Collar 1 8 Rubber damper 1 9 Gasket 1 10 O2 sensor 1 coupler 1 Disconnect 10 4 9 5 8 6 1 3 2 7 4 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 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 28 Nm 2 8 m kgf 20 ft Ibf T R 47 Nm 4 7 m kgf 34 ft Ibf T R 45 Nm 4 ...

Page 299: ...ket 2 For installation reverse the removal proce dure 11 12 13 14 4 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 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 28 Nm 2 8 m kgf 20 ft Ibf T R 47 Nm 4 7 m kgf 34 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R ...

Page 300: ...connect Refer to CLUTCH on page 5 52 Shift arm Refer to SHIFT SHAFT on page 5 72 Radiator Refer to RADIATOR on page 6 1 Thermostat Refer to THERMOSTAT on page 6 4 Radiator outlet pipe Refer to WATER PUMP on page 6 6 1 Sidestand switch coupler 1 Disconnect 2 Sidestand 1 3 Ignition coil coupler 4 Disconnect 1 3 3 2 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 63 Nm 6 3 m kgf 46 ft...

Page 301: ...perature sensor coupler 1 Disconnect 7 Oil level switch coupler 1 Disconnect 8 Neutral switch coupler 1 Disconnect 9 Starter motor lead 1 Disconnect 10 Engine ground lead 1 Disconnect 11 Negative battery lead 1 Disconnect For installation reverse the removal proce dure 10 7 8 11 9 6 4 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 63 Nm 6 3 m kgf 46 ft Ibf T R 5 ...

Page 302: ...ollar front right outside 4 5 Engine mounting collar front right inside 2 6 Engine mounting nut 1 7 Engine mounting bolt rear right lower side 1 100 mm 3 94 in 8 Engine mounting bolt rear left lower side 1 110 mm 4 33 in 8 3 4 5 4 6 7 3 4 5 4 2 1 1 23 Nm 2 3 m kgf 17 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 7...

Page 303: ...front left side 2 11 Engine mounting bolt rear upper side 1 12 Engine 1 13 Engine positioning bolt 1 For installation reverse the removal proce dure 9 10 9 10 12 11 13 23 Nm 2 3 m kgf 17 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R ...

Page 304: ... Make sure that the flange on the engine posi tioning bolt contacts the engine 4 Install Engine mounting nut 13 TIP Do not fully tighten the nut 5 Tighten Engine mounting bolts front left side 7 TIP Make sure that the engine contacts the frame 6 Tighten Engine mounting bolt rear left lower side 3 Engine mounting bolt rear right lower side 4 Engine mounting nut 13 Engine mounting bolts front right ...

Page 305: ... O mark a on the damper is facing inward 3 Install Rubber cover 1 Muffler cover 2 TIP Install the rubber cover so that its lip a is fold ed as shown in the illustration Make sure that the muffler cover contacts the muffler cover support b Installed depth b 1 0 mm 0 04 in T R Muffler bolt 47 Nm 4 7 m kgf 34 ft lbf 6 6 7 7 3 5 10 9 8 13 4 8 11 2 12 1 New b a 1 New T R Muffler cover bolt 7 Nm 0 7 m k...

Page 306: ... bodies Refer to THROTTLE BODIES on page 7 5 1 Cylinder head breather hose 1 2 Ignition coil coupler 4 Disconnect 3 Ignition coil 4 4 Spark plug 4 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Breather plate 1 8 Breather plate gasket 1 2 5 4 4 4 6 3 1 7 8 6 3 LT New New 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 13 Nm 1 3 m kgf 9 4...

Page 307: ...Job Parts to remove Q ty Remarks 9 Timing chain guide upper side 1 For installation reverse the removal proce dure 4 6 3 9 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 13 Nm 1 3 m kgf 9 4 ft Ibf T R ...

Page 308: ...hain tensioner gasket 1 3 Intake camshaft cap 3 4 Exhaust camshaft cap 1 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Decompressor lever 2 1 10 Decompressor lever 1 1 9 10 3 4 1 2 5 6 8 7 6 6 New M M E E E E 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 ...

Page 309: ... ty Remarks 11 Decompressor lever pin 2 For installation reverse the removal proce dure 11 11 6 6 M M E E E E 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R ...

Page 310: ...driver 2 Remove Plastic band 1 3 Remove Starter motor lead 1 Stator coil lead 2 4 Remove Brake hose joint bolt front brake master cyl inder to hydraulic unit 1 5 Remove Brake hose joint bolt hydraulic unit to left front brake caliper 1 6 Remove Clutch hose holder bolt 1 7 Remove Brake hose holders 1 8 Remove Clutch pipe 1 Brake pipe front brake master cylinder to hy draulic unit 2 1 2 a 1 1 1 2 1 ...

Page 311: ...e b Align the K mark a with the crankcase mat ing surface b TIP When the K mark a is aligned with the crank case mating surface b check that the match mark c on the intake camshaft sprocket and match mark d on the exhaust camshaft sprock et are aligned with the cylinder head surface e Also check that the hole f in the intake cam shaft is aligned with the match mark g on the intake camshaft cap If ...

Page 312: ...or holding tool 3 loosen the intake camshaft sprocket bolts and exhaust camshaft sprocket bolts EAS23850 CHECKING 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 01235 Universal magneto rotor holder YU 01235 1 2 3 3 1 Camshaft lobe dimensions...

Page 313: ...ng the camshaft journal to camshaft 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 EAS23P1090 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a ...

Page 314: ...rod can smoothly move out from the timing chain tensioner housing in direction d If not smooth replace the timing chain tensioner assembly EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system TIP Check that the decompression pins 1 projects from the camshaft Check that the decompression cams 2 and decompression pins 1 moves smoothly EAS24000 INSTALLING THE CAMSHAFTS 1 Align K ma...

Page 315: ... 1 Exhaust camshaft sprocket 2 NOTICE ECA23P1077 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine TIP Install the cam lobe 1 a at the position shown in the illustration Tighten the camshaft sprocket bolt with the ro tor holding tool 3 4 Install Timing chain 1 Exhaust camshaft 2 Exhaust camshaft cap T R...

Page 316: ... onto the cylinder head TIP Make sure the match mark a on the intake camshaft sprocket are aligned with the cylinder head edge Make sure that the distance between the E mark b on the exhaust camshaft sprocket and the I mark c on the intake camshaft sprocket is 4 5 timing chain links d as shown in the il lustration b Install the intake camshaft caps and then fin ger tighten the intake camshaft cap ...

Page 317: ...e timing chain tensioner in the cylin der block d Push the timing chain guide 5 as shown in the illustration to release the timing chain ten sioner rod e Check that the timing chain is taut If the chain is slack reinstall the timing chain ten sioner 7 Remove Plastic locking tie TIP Remove the plastic locking tie that was used to fasten the timing chain to the intake camshaft sprocket 8 Turn Cranks...

Page 318: ... 3 onto the mating surfaces of the cylinder head cover and cylinder head cover gaskets Apply Yamaha bond No 1215 4 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head Install a cylinder head cover gasket 1 and then cut the portions a 2 Install Cylinder head cover NOTICE ECA23P1074 When installing the cylinder head cover to the cylinder head make sure that the cylin der he...

Page 319: ...lder into the hole b in the inner section 7 Install Clutch hose holder bolt 1 TIP Insert the tab a on the clutch hose holder into the slot b in the frame 8 Install Brake hose joint bolt hydraulic unit to left front brake caliper 1 Brake hose joint bolt front brake master cyl inder to hydraulic unit 2 TIP Make sure that the tab a on the brake hose joint bracket contacts the side of the brake hose j...

Page 320: ...CAMSHAFTS 5 25 9 Install Stator coil lead Starter motor lead Plastic bands Wire harness holder a b 2 ...

Page 321: ...ylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide exhaust side 1 For installation reverse the removal proce dure 5 2 3 4 1 4 1 1 LT LT New New New New New E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 1st...

Page 322: ...k plug bore threads Valve seats 2 Check Cylinder 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 g...

Page 323: ...ther to reach the specified an gle in the proper tightening sequence as shown TIP Tighten each bolt to the specified angle before tightening the next bolt to the specified torque e Tighten the cylinder head bolts in the proper tightening sequence as shown M12 185 mm 1 6 M6 125 mm 7 8 T R Cylinder head bolt 1 6 1st 20 Nm 2 0 m kgf 14 ft lbf T R Cylinder head bolt 1 6 2nd 30 Nm 3 0 m kgf 22 ft lbf C...

Page 324: ...head Refer to CYLINDER HEAD 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 Exhaust valve 4 7 Intake valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 For installation reverse the removal proce dure New New New New E E M M M M M M M M 8 9 8 10 9 5 1 2 3 4 10 6 7 2 3 4 1 3 3 5 ...

Page 325: ...Pour a clean 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 sea...

Page 326: ...2 and valve guide remover 1 c After 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 ...

Page 327: ...lies 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 installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 Valve guide i...

Page 328: ...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 329: ...age 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 22 mm 1 58 in Limit 38 21 mm 1 50 in Free length exhaust 40 22 mm 1 58 in Limit 38 21 mm 1 50 in Installed compression spring force intake 192 00 220 00 N 19 58 22 43 kgf...

Page 330: ...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 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve Recommended lubricant Molybdenum disulfide oil M M 2 1 New 3 1...

Page 331: ...er 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 their original position Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil ...

Page 332: ...head Refer to CYLINDER HEAD on page 5 26 1 Water jacket cover 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal proce dure 5 5 6 7 8 9 10 4 4 2 3 1 LT LT E E New New E New LS LS New E New 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 333: ...removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to both of the cylinders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance...

Page 334: ...earance 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 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown Diameter D 97 965 97 980 mm 3 8569 3 8575 in b 8 0 mm 0 31 in from the bottom edge of the pi...

Page 335: ...Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set EAS24470 INSTALLING THE PISTONS AND CYLINDER The following procedure applies to both of the pistons a 40 0 mm 1 57 in Piston ring Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in 2nd ring Limit 0 60 mm 0 0236 in End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Oil ...

Page 336: ...m falling into the crank case Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder numbering order starting from the left 1 to 2 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket 6 Install Cylinder 1 TIP Whi...

Page 337: ...CYLINDER AND PISTONS 5 42 1 ...

Page 338: ...AL on page 5 3 Fuel tank Refer to FUEL TANK on page 7 1 1 Stator coil coupler 1 Disconnect 2 Engine guard bracket 1 3 Holder fuel tank overflow hose and fuel tank breather hose 1 4 Holder sidestand switch lead and oil level switch lead 1 5 Generator cover 1 6 Generator cover gasket 1 LT LT E LT E E LT LT E E E LT LT New 4 5 3 8 3 2 6 1 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 339: ...rter clutch idle gear shaft 1 13 Starter clutch idle gear 1 14 Torque limiter 1 15 Starter clutch gear 1 16 Starter clutch 1 17 Washer 1 For installation reverse the removal proce dure LT LT E LT E E LT LT E E E LT LT 14 13 12 15 16 17 3 8 10 11 7 7 9 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 130 Nm 13 m kgf 94 ft l...

Page 340: ...r is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the de...

Page 341: ...ller assembly with the arrow mark a is toward the generator rotor 3 While holding the generator rotor with the sheave holder 4 tighten the starter clutch bolts 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 ...

Page 342: ... the generator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 43 Yamaha bond No 1215 90890 85505 Three Bond No 1215 T R Generator cover bolt M6 55 12 Nm 1 2 m kgf 8 7 ft lbf LOCTITE Generator cover bolt M6 25 12 Nm 1 2 m kgf 8 7 ft lbf 3 1 2 New ...

Page 343: ...r motor Order Job Parts to remove Q ty Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure 1 2 12 Nm 1 2 m kgf 8 7 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R New LS ...

Page 344: ... remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor rear cover 1 3 Brush holder set 1 4 Armature assembly 1 5 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 1 4 2 3 4 5 5 Nm 0 5 m kgf 3 6 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R New New ...

Page 345: ...esistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set 6 Check Gear teeth Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Mode...

Page 346: ...r motor front cover EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers a a b b 2 1 3 ...

Page 347: ...ler cap 1 2 Crankshaft end accessing screw 1 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Clutch cover damper plate 1 7 Clutch cover damper 1 For installation reverse the removal proce dure 2 3 14 1 New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R LS LS New 4 7 6 5 4 5 LT LT ...

Page 348: ...Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Bearing 1 6 Short clutch push rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 7 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New E E E E E LS LS E 2 9 11 9 11 10 3 4 6 5 7 1 6 8 ...

Page 349: ...5 Clutch plate 1 16 Friction plate 3 1 Inside diameter 135 mm 5 31 in 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Clutch boss 1 20 Thrust washer 1 21 Clutch housing 1 22 Spacer 1 23 Bearing 1 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New New New E E E E E LS LS E 14 12 15 16 17 21 18 19 20 22 23 13 16 6 ...

Page 350: ...g the clutch Order Job Parts to remove Q ty Remarks 24 Spacer 1 25 Thrust plate 1 For installation reverse the removal proce dure 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New E E E E E LS LS E 24 25 6 ...

Page 351: ...ter cylinder reservoir diaphragm holder 1 7 Clutch master cylinder reservoir diaphragm 1 8 Lower hand shield bracket 1 9 Clutch lever 1 10 Bushing 1 3 10 5 6 7 9 8 2 1 4 S New New LT 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T...

Page 352: ...er holder 1 17 Clutch master cylinder 1 For installation reverse the removal proce dure 16 11 17 14 15 12 13 S New New LT 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ib...

Page 353: ...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 BF S ...

Page 354: ...n page 3 13 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 New New LT LT LT LT LS 6 5 5 4 1 3 7 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 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 355: ... plates Clutch plates TIP Before removing friction plate 1 put an identifi cation mark a on the plate 4 Remove Long clutch push rod 1 TIP Push the long clutch push rod into the clutch re lease cylinder side of the engine and remove it from the clutch side of the engine 5 Straighten the clutch boss nut rib a 6 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch h...

Page 356: ...1 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS25130 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate retainer Damage Replace Friction plate 1 2 thick...

Page 357: ...e 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 EAS25191 CHECKING THE CLUTCH PUSH RODS 1 Check Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit with a ...

Page 358: ...with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss nut 3 at cutouts b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates TIP First install a friction plate and then alternate between a clutch plate and a friction plate Fricti...

Page 359: ...arely require disas sembly Therefore always follow these preventive measures Never disassemble clutch components un less absolutely necessary If any connection on the hydraulic clutch system is disconnected the entire clutch system must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal clutch com ponents Use only clean or new clutch fluid for...

Page 360: ...linder reservoir Cracks damage Replace Clutch master cylinder reservoir diaphragm Damage wear Replace 4 Check Clutch hose Cracks damage wear Replace EAS25300 ASSEMBLING THE CLUTCH MASTER CYLINDER WARNING EWA13340 Before installation all internal clutch com ponents must be cleaned and lubricated with clean or new clutch fluid Never use solvents on internal clutch com ponents as they will cause the ...

Page 361: ...lready in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock NOTICE ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any ...

Page 362: ... 2 Install Clutch release cylinder plate 1 Dowel pins Clutch release cylinder TIP Install the clutch release cylinder plate with its OUT mark a facing out 3 Check Clutch hose gaskets 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EWA23P1014 Proper clutch hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 43 NOTICE ECA23P1042 When installing the clutch ho...

Page 363: ... lower the boiling point of the clutch fluid and could cause vapor lock NOTICE ECA13420 Clutch fluid may damage painted surfaces or plastic 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 that the top of the reservoir is horizontal 5 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on p...

Page 364: ... CHASSIS on page 4 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 43 Clutch cover Refer to CLUTCH on page 5 52 1 Crankshaft position sensor coupler 1 Disconnect 2 Crankshaft position sensor 1 3 Pickup rotor 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R New New LT LS ...

Page 365: ...gn the groove a in the crankshaft sprocket with the projection b on the pickup rotor Install the pickup rotor with K mark facing out 2 Tighten Pickup rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Install O rings Crankshaft position sensor Crankshaft position sensor holder Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 1 ...

Page 366: ...nkshaft position sensor 1 and pickup rotor 2 a Out of specification Reinstall or replace T R Crankshaft position sensor hold er bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Gap between the crankshaft po sition sensor and pickup rotor 1 0 mm 0 04 in a 2 1 ...

Page 367: ...to CLUTCH on page 5 52 1 Shift rod 1 TIP The shift rod locknut shift pedal side has left hand threads 2 Shift arm 1 3 Circlip 1 4 Washer 1 5 Stopper lever spring 1 6 Shift shaft 1 7 Washer 1 8 Circlip 1 9 Washer 1 1 2 3 4 6 9 8 5 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R LT E LS New New E E 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 368: ...marks 10 Stopper lever 1 11 Spacer 1 12 Shift shaft spring 1 13 Shift shaft spring stopper 1 14 Oil seal 1 15 Bearing 2 For installation reverse the removal proce dure 14 15 15 13 12 11 10 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R LT E LS New E E 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 369: ...d of the shift shaft spring onto the shift shaft spring stopper 4 Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 3 Install Shift arm 1 TIP Align the match mark a in the shift shaft with the punch mark b in the shift arm EAS21380 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determine...

Page 370: ...direction a or b until the specified installed shift rod length is ob tained TIP Make sure that the distances c and d are equal c Tighten both locknuts to specification d Make sure the installed shift rod length is within specification Direction a Installed shift rod length increases Direction b Installed shift rod length decreases T R Locknut 8 Nm 0 8 m kgf 5 8 ft lbf b 1 d a 2 1 c ...

Page 371: ... cover gasket 1 3 Oil strainer oil pan 1 4 Oil level switch coupler 1 Disconnect 5 Oil level switch lead holder 1 6 Oil level switch 1 7 Water pump breather hose holder 1 8 Oil pan 1 8 6 1 4 5 7 2 3 6 17 New New New New New New New LT LS LS LS FWD New LT LT LT FWD LS LS 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 2...

Page 372: ...assembly 1 13 Dowel pin 2 For installation reverse the removal proce dure 12 12 13 10 11 11 10 9 6 17 New New New New New New New LT LS LS LS FWD New LT LT LT FWD LS LS 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 20 Nm 2 0 m kgf 14 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 373: ...er oil pump 1 2 Pin 2 3 Spring 1 4 Relief valve 1 5 Oil pump inner rotor 1 1 6 Oil pump outer rotor 1 1 7 Pin 1 8 Oil pump housing cover 1 9 Pin 2 10 Pin 1 11 Oil pump driven gear 1 12 Washer 1 E E E 1 8 12 9 9 6 11 10 7 2 4 3 2 5 6 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 374: ...Order Job Parts to remove Q ty Remarks 13 Oil pump inner rotor 2 1 14 Oil pump outer rotor 2 1 15 Oil pump housing 1 For assembly reverse the disassembly pro cedure E E E 14 13 6 15 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 375: ... the oil pump assembly 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24971 CHECKING THE RELIEF VALVE 1 Check Relief valve Spring Damage wear Replace the oil pump as sembly EAS24980 CHECKING THE OIL PIPE 1 Check Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to ...

Page 376: ...er to CHECKING THE OIL PUMP on page 5 80 EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Gasket Oil pan TIP Tighten the oil pan bolts in stages and in a criss cross pattern EAS23P1031 INSTALLING THE OIL STRAINER COVER 1 Apply Sealant on to the oil strainer cover and oil strainer cover gasket TIP Apply Three Bond No 1541C 1 onto the mat ing surfaces of the oil strainer cover and oil strainer c...

Page 377: ... Starter motor assembly Refer to ELECTRIC STARTER on page 5 48 Oil pump assembly Refer to OIL PUMP on page 5 76 Clutch housing Clutch release cylinder Refer to CLUTCH on page 5 52 Middle driven pinion gear assembly Refer to MIDDLE GEAR on page 5 113 Water pump assembly Refer to WATER PUMP on page 6 6 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 E E E LT LT FWD E New 2 1 10 10 Nm 1 0 m kg...

Page 378: ...shaft 1 5 Rear balancer 1 NOTICE ECA23P1075 The rear balancer should not be disas sembled 6 Rear balancer holder 1 7 Dowel pin 2 For installation reverse the removal proce dure E E E LT LT FWD E 7 6 10 5 4 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 379: ...1 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 123 LS New New E E E E E E New New FWD LT LT LT LT E 1 2 11 10 4 6 6 6 7 4 5 6 3 8 9 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 12 Nm 1 2 m kgf 8 7 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 24 Nm 2 4 m kgf 17 f...

Page 380: ... 7 4 12 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 12 Nm 1 2 m kgf 8 7 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 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 28 Nm 2 8 m kgf 20 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 1st 2nd Final Specified ang...

Page 381: ... Transmission Refer to TRANSMISSION on page 5 103 1 Oil nozzle 1 1 2 Oil nozzle 2 1 3 Oil nozzle 3 1 4 Oil plug holder 1 For installation reverse the removal proce dure FWD New New New New LT LS LS LT LT 1 4 3 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 8 Nm 0 8 m kgf 5 8 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 0 5 Nm 0 05 m kgf 0 36 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R...

Page 382: ...ss pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence M10 130 mm bolts 1 6 M8 78 mm bolts 7 12 M8 80 mm bolts 13 19 M8 60 mm bolts 20 21 30 32 M6 50 mm bolts 22 24 27 29 M6 65 mm bolts 23 28 3 Remove Upper crankcase Oil...

Page 383: ...haft sprockets and crankshaft as a set Timing chain guide intake side Damage wear Replace EAS23P1094 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle Damage wear Replace Oil passage Obstruction Blow out with compressed air EAS25680 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft journal bearings with the recommended lubricant Front balancer shaf...

Page 384: ...l O rings Crankcase bolts WARNING EWA23P1015 Replace the bolts 1 6 with new ones TIP Before installing the crankcase bolts 7 12 install the O rings onto the bolts making sure that each O ring contacts the bolt flange Lubricate the bolts 1 6 threads and wash ers with engine oil Lubricate the bolts 7 32 threads and mating surfaces with engine oil Finger tighten the crankcase bolts M10 130 mm bolts 1...

Page 385: ... 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 ECA23P1045 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 note that the angle from one corner to another is 60 10 Tighten Crankcase bo...

Page 386: ... a facing up 12 Install Oil delivery passage cover 1 T R Crankcase bolt 7 21 30 32 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt 22 29 10 Nm 1 0 m kgf 7 2 ft lbf 11 13 16 17 18 19 20 21 26 27 28 29 A 9 12 7 8 15 22 24 25 14 10 23 A Lower crankcase B Upper crankcase T R Middle drive pinion gear bearing retainer bolt 28 Nm 2 8 m kgf 20 ft lbf LOCTITE T R Oil delivery passage cover 12 Nm 1 2 m kgf 8 7 ft ...

Page 387: ... Rear balancer shaft Rear balancer shaft retainer a Check that the match mark a in the front bal ancer shaft is aligned with the crankcase mating surface b b Align the punch mark c in the rear balancer with the match mark d on the upper crank case c Install the rear balancer shaft and then tight en the bolt to specification 1 2 a b c d T R Rear balancer shaft retainer bolt 12 Nm 1 2 m kgf 8 7 ft l...

Page 388: ... balancer shaft 1 NOTICE ECA23P1076 The front balancer shaft should not be disassembled 2 Front balancer shaft journal lower bearing 3 3 Front balancer shaft journal upper bearing 3 4 Crankshaft 1 5 Crankshaft journal lower bearing 3 6 Crankshaft journal upper bearing 3 7 Connecting rod cap 2 M M M M FWD E E E E E E E E New New New 1 3 3 3 2 2 2 6 6 4 5 7 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specifie...

Page 389: ...t balancer Order Job Parts to remove Q ty Remarks 8 Big end lower bearing 2 9 Connecting rod 2 10 Big end upper bearing 2 For installation reverse the removal proce dure M M M M FWD E E E E E E E E New New New 9 10 8 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specified angle 145 155 T R ...

Page 390: ...g procedure applies to all of the con necting rods 1 Remove Connecting rod cap Connecting rod Big end bearings TIP Identify the position of each connecting rod cap connecting rod and big end bearing so that it can be reinstalled in its original place EAS26070 CHECKING THE CRANKSHAFT 1 Measure Crankshaft runout Out of specification Replace the crank shaft 2 Check Crankshaft journal surfaces Cranksh...

Page 391: ...rement has been completed e Tighten the bolts to specification in the tight ening sequence cast on the crankcase Refer to CRANKCASE on page 5 82 f Remove the upper crankcase and the crank shaft journal upper bearings g 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 c...

Page 392: ...crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end 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 Do not mov...

Page 393: ...ce is out of specification select re placement big end bearings 2 Select Big end bearings P1 P2 TIP The numbers A stamped into the crankshaft web and the numbers B on the connecting rods are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re s...

Page 394: ...f Plastigauge 2 on each front balancer shaft journal TIP Do not put the Plastigauge over the oil hole in the front balancer shaft journal d Install the front balancer shaft journal upper bearings 3 into the upper crankcase and as semble the crankcase halves TIP Align the projections c of the front balancer shaft journal upper bearings with the notches d in the upper crankcase Do not move the front...

Page 395: ...ubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the Y marks c on ...

Page 396: ...t Instead replace the connecting rod bolt and nut with a new one and perform the procedure again NOTICE ECA23P1049 Do not use a torque wrench to tighten the connecting rod nut to the specified angle Tighten the nut until it is at the specified an gle TIP On a hexagonal nut note that the angle from one corner to another is 60 EAS26200 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bea...

Page 397: ... bearings into the lower crankcase TIP Align the projections a on the front balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each front balancer shaft jour nal bearing in its original place 2 Install Front balancer shaft 1 TIP Align the punch mark a in the crankshaft with the punch mark b in the front balancer shaft c Oil groove c 1 a b a 1 b 1 b a ...

Page 398: ... middle drive pinion gear assembly 1 2 Shift drum lower retainer 1 3 Shift fork lower guide bar 1 124 5 mm 4 90 in 4 Spring 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum upper retainer 1 8 Shift fork upper guide bar 1 127 8 mm 5 03 in 9 Shift fork C 1 10 Shift drum assembly 1 LT LT LT LT E E E FWD E E E E LT LT LT LT 2 1 4 4 3 7 10 8 9 6 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft I...

Page 399: ...assembly and shift forks Order Job Parts to remove Q ty Remarks 11 Main axle assembly 1 12 Bearing 1 For installation reverse the removal proce dure LT LT LT LT E E E FWD E E E E LT LT LT LT 12 11 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 400: ...irclip 1 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed lock washer retainer 1 5 6th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 1 8 Circlip 1 9 3rd 4th pinion gear 1 10 Circlip 1 11 Toothed washer 1 12 5th pinion gear 1 1 2 3 4 5 6 7 8 9 10 11 12 New New New M M M M M M M M E ...

Page 401: ...bling the main axle Order Job Parts to remove Q ty Remarks 13 Collar 1 14 Bearing housing 1 15 Spacer 1 16 Bearing 1 17 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure 13 17 16 15 14 M M M M M M M M E ...

Page 402: ... Middle drive pinion gear assembly Refer to MIDDLE GEAR on page 5 113 1 Bearing 1 2 Washer 1 3 1st wheel gear 1 4 Collar 1 5 5th 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 New M E 1 6 2 7 8 9 10 11 3 4 5 M M M M M M ...

Page 403: ...to remove Q ty Remarks 12 4th wheel gear 1 13 Collar 1 14 Toothed washer 1 15 Circlip 1 16 6th wheel gear 1 17 Circlip 1 18 Toothed washer 1 19 2nd wheel gear 1 20 Collar 1 21 Drive axle 1 For assembly reverse the disassembly pro cedure New New M E 12 13 19 20 21 14 15 16 18 17 M M M M M M ...

Page 404: ... to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set 4 Check Springs Cracks damage Replace 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...

Page 405: ...r movement Rough movement Replace the defective part s EAS23P1046 ASSEMBLING THE MAIN 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 in the groove a in the axle align the projection on the retai...

Page 406: ...ign the bearing housing hole with the corresponding hole in the upper crankcase 3 Install Shift drum assembly Shift fork C Shift fork upper guide bar Shift fork R Shift fork L Springs Shift fork lower guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 4 Install Shift drum upper retainer 1 Shift drum lower reta...

Page 407: ...etainer with its OUT mark a facing outward Align the projection b on the shift fork upper guide bar with the slot c in the shift drum up per retainer 5 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly b c a 2 1 ...

Page 408: ...r damper plate 1 5 Middle gear side cover damper 1 6 Circlip 4 7 Bearing 4 8 Universal joint 1 9 Middle driven pinion gear assembly 1 10 Middle driven pinion gear shim Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 121 and ALIGNING THE MIDDLE GEAR on page 5 123 10 8 10 6 9 7 7 7 7 6 6 6 1 2 6 3 3 4 5 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 LT LT 33 Nm 3 3 m kgf 24 ft...

Page 409: ...ven pinion gear 1 15 Expander 1 16 Bearing 1 17 Oil seal 1 18 Bearing 1 19 Bearing race 2 20 Middle driven pinion gear bearing housing 1 For installation reverse the removal proce dure 14 12 13 11 16 19 18 19 20 17 6 4 15 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R LT LT 33 Nm 3 3 m kgf 24 ft Ibf T R LT E LS LS LS LT LT LS LS LS LS LS New New New New E E FWD ...

Page 410: ...earing retainer 1 2 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 123 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 E LT FWD E M M 7 8 9 10 5 4 1 4 6 3 2 28 Nm 2 8 m kgf 20 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R ...

Page 411: ...ove Q ty Remarks 11 Middle drive pinion gear nut 1 12 Middle drive pinion gear 1 13 Bearing 1 14 Middle drive pinion gear bearing housing 1 For installation reverse the removal proce dure E LT FWD E M M New 11 12 14 13 4 28 Nm 2 8 m kgf 20 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R ...

Page 412: ...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 and the 20 mm 0 79 in diameter attachment loosen the uni versal joint yoke nut Place a rag between the attachment and the universal joint yoke as shown in the illustration EAS23P1035 REMOVING THE MIDDLE DRIVE PINION GEAR ASSE...

Page 413: ...ear Galling pitting wear Replace the middle drive pinion gear and middle driven pinion gear as a set 2 Check Torque damper cam surface Scratches wear Replace 3 Check Spring Cracks damage Replace 4 Check Bearings Damage pitting Replace EAS23P1039 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 mi...

Page 414: ...aring 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 and the 20 mm 0 79 in diameter attachment tighten the uni versal joint yoke nut Place a rag between the attachment and the universal joint yoke as shown in the illustration After tightening the nut check the operation of the middle driven pinion gear assembly If the...

Page 415: ... Adjust the backlash EAS23P1042 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1 Install Middle driven pinion gear shim s 1 Middle driven pinion gear assembly TIP Install the shim s so that the tabs are positioned as shown in the illustration 2 Install Universal joint 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...

Page 416: ...he middle drive pinion gear 1 with the middle gear backlash tool 2 TIP Finger tighten the middle gear backlash tool bolts b Make sure the dial gauge plunger contacts the measuring point on the centerline of the yoke bearing hole as shown c While gently turning the universal joint yoke back and forth measure the middle gear backlash TIP Measure the middle gear backlash at four posi tions Rotate the...

Page 417: ... until the dial gauge reads 0 045 0 090 mm 0 002 0 004 in 6 Measure Crankcase to middle driven pinion gear bearing housing clearance with a thickness gauge 7 Select Middle driven pinion gear shim s 1 a Shims are only available in 0 05 mm incre ments therefore round off to the hundredth s digit of the calculated thickness and select the appropriate shim s with the following chart b For example the ...

Page 418: ...ed on the upper crankcase middle driven pinion gear and bearing housings b To find middle drive pinion gear shim thick ness A use the following formula a a numeral on the middle drive pinion gear bearing housing to be divided by 100 and added to 14 00 b 52 20 c a numeral on the upper crankcase to be divided by 100 and added to 66 00 Example If the middle drive pinion gear bearing hous ing is marke...

Page 419: ...0 g is 99 00 Example If the middle driven pinion gear bearing hous ing is marked 17 d is 56 12 i e 55 95 0 17 56 12 If the middle driven pinion gear is marked 03 e is 13 43 i e 13 40 0 03 13 43 If the middle driven pinion gear is marked 02 f is 56 98 i e 57 00 0 02 56 98 If the upper crankcase is marked 93 g is 98 93 i e 98 00 0 93 98 93 TIP If the upper crankcase is marked 00 g is 99 00 B 56 12 1...

Page 420: ...MIDDLE GEAR 5 125 Shims are supplied in the following thickness es Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle driven pinion gear shim Thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 ...

Page 421: ...IATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 8 CHECKING THE WATER PUMP 6 8 ASSEMBLING THE WATER PUMP 6 8 INSTALLING THE WATER PUMP 6 10 ...

Page 422: ...se 1 3 Coolant reservoir cap 1 4 Coolant reservoir 1 5 Water pump inlet hose 1 6 Radiator outlet hose 1 7 Radiator outlet pipe 1 2 3 4 1 6 5 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 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 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 5 ...

Page 423: ...4 Radiator inlet hose 1 For installation reverse the removal proce dure 14 9 11 8 13 10 12 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 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 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 f...

Page 424: ...s and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressur...

Page 425: ...to THROTTLE BODIES on page 7 5 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Copper washer 1 4 Radiator inlet hose 1 5 Thermostat cover 1 6 Thermostat 1 For installation reverse the removal proce dure 18 Nm 1 8 m kgf 13 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R New 1 2 3 4 5 6 ...

Page 426: ...e it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather hole a facing forward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 3 Check Cooling system Leaks Repair or ...

Page 427: ...on page 3 28 1 Water pump inlet hose 1 2 Lead holder 1 3 Water pump assembly 1 4 Water pump outlet pipe 1 5 Water pump breather hose 1 For installation reverse the removal proce dure 5 1 2 3 4 New LS New LS LT LT 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 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R ...

Page 428: ... Gasket 1 3 Circlip 1 4 Impeller shaft 1 5 Water pump seal 1 6 Bearing 1 7 Oil seal 1 8 Water pump housing 1 9 Rubber damper holder 1 10 Rubber damper 1 11 Water pump seal assembly 1 For assembly reverse the disassembly pro cedure 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 4 10 11 9 5 7 2 8 6 3 New New New New New New New E ...

Page 429: ...ater pump housing cover Water pump housing Impeller shaft Water pump seal Oil seal Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet hose Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Rubber damper holder 1 Rubber damper 2 TIP Before installing the rubber damper apply tap water or coolant onto its outer surfa...

Page 430: ...al tools 5 Install Impeller shaft 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the bearing After installation check that the impeller shaft rotates smoothly 1 Straightedge 2 Impeller Installed depth of oil seal a 0 5 1 0 mm 0 02 0 04 in 2 1 New 3 a 2 1 New New Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft b...

Page 431: ...the front balancer shaft 2 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 1 a 2 b ...

Page 432: ...WATER PUMP 6 11 ...

Page 433: ...THE INJECTORS BEFORE REMOVING 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 CHECKING THE THROTTLE BODY JOINTS 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 10 CHECKING THE FUEL PRESSURE 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 12 INSTALLING THE THROTTLE BODY JOINTS 7 ...

Page 434: ...l pump coupler 1 Disconnect 3 Fuel sender coupler 1 Disconnect 4 Fuel hose holder 1 5 Fuel hose 1 6 Fuel tank overflow hose 1 Disconnect 7 Fuel tank breather hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump 1 10 Rear fuel tank bracket 1 New LS 1 2 6 7 3 5 4 9 4 6 8 10 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 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 ...

Page 435: ... lock assembly 1 12 Seat lock cable 1 Disconnect For installation reverse the removal proce dure New LS 4 6 11 12 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 16 Nm 1 6 m kgf 12 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R ...

Page 436: ... be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like 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 Obstr...

Page 437: ...of the hose in the direction of the arrow shown 3 Install Fuel hose fuel pump side Fuel hose holder NOTICE ECA23P1001 When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector securely onto the fuel tank until a distinct click is heard an...

Page 438: ...n sensor coupler 1 Disconnect 3 Throttle servo motor coupler 1 Disconnect 4 Injector 2 coupler 1 Disconnect 5 Injector 1 coupler 1 Disconnect 6 Intake air pressure sensor coupler 1 Disconnect 7 Throttle cable decelerator cable 1 Disconnect 8 Throttle cable accelerator cable 1 Disconnect 9 Throttle body joint clamp screw 2 Loosen 7 8 1 2 3 4 5 6 9 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 ...

Page 439: ...Parts to remove Q ty Remarks 10 Throttle bodies 1 11 Throttle body joint 2 For installation reverse the removal proce dure 10 11 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R ...

Page 440: ... 2 Negative pressure hose 1 3 Accelerator position sensor 1 4 Throttle position sensor 1 5 Fuel rail 1 6 Injector 2 For installation reverse the removal proce dure 5 6 6 1 2 3 4 New New 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 441: ...check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 155 EAS23P1080 CHECKING AND CLEANING THE THROTTLE BODIES TIP Clean the throttle bodies only if they cannot be synchronized using the bypass air screws Be fore cleaning the throttle bodies check the fol lowing items Valve clearance Spark plugs Air filter ...

Page 442: ...e inside of the throttle bodies to remove any carbon deposits TIP Do not allow any petroleum based solvent to enter the opening for the injectors Do not apply any petroleum based solvent to the portions of the throttle valve shafts be tween the throttle bodies e Remove the carbon deposits from the inside of each throttle body in a downward direction from the air filter case side of the throttle bo...

Page 443: ...hocks or excessive force replace it If installing the original fuel rail and screws remove the white paint marks using a cleaning solvent Otherwise paint chips on the screw seats could prevent the screws from being tightened to the specified torque 1 Install a new seals onto the end of each injec tor 2 Install the injectors 1 to the fuel rail 2 3 Install the injector assemblies to the throttle bod...

Page 444: ...bolts 1 and holdup the fuel tank NOTICE ECA23P1003 When lifting up the fuel tank be careful not to pull the fuel tank overflow hose and fuel tank breather hose b Remove the fuel hose holder 2 and then disconnect the fuel hose 3 from the fuel tank WARNING EWA23P1032 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out wh...

Page 445: ...utton 1 and right set button 2 turn the main switch to ON and continue to press the buttons for 8 seconds more TIP dIAG appears on the odometer LCD f Diagnostic code number d 01 is selected g Adjust the position of the throttle position sen sor angle so that 9 20 can appear in the meter h After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 EAS23P1085 A...

Page 446: ...alue is not 97 113 adjust the accel erator position sensor angle m Select the diagnostic code number d 15 n Turn the throttle grip to the fully closed posi tion o Check the meter display value If the meter display value is not 9 25 adjust the acceler ator position sensor angle p Turn the throttle grip to the fully open position q Check the meter display value If the meter display value is not 97 1...

Page 447: ...SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 34 TROUBLESHOOTING DETAILS 8 36 DIAGNOSTIC CODE TABLE 8 73 FUEL PUMP SYSTEM 8 75 CIRCUIT DIAGRAM 8 75 TROUBLESHOOTING 8 77 IMMOBILIZER SYSTEM 8 79...

Page 448: ...131 ELECTRICAL COMPONENTS 8 133 CHECKING THE SWITCHES 8 137 CHECKING THE BULBS AND BULB SOCKETS 8 140 CHECKING THE FUSES 8 141 CHECKING AND CHARGING THE BATTERY 8 142 CHECKING THE RELAYS 8 145 CHECKING THE TURN SIGNAL HAZARD RELAY 8 146 CHECKING THE RELAY UNIT DIODE 8 147 CHECKING THE IGNITION COILS 8 147 CHECKING THE IGNITION SPARK GAP 8 148 CHECKING THE CRANKSHAFT POSITION SENSOR 8 148 CHECKING ...

Page 449: ......

Page 450: ...R BLACK Br W BLACK B L W BLACK W BLACK L B B L BLACK NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 L...

Page 451: ...t 24 Neutral switch 25 Sidestand switch 28 Crankshaft position sensor 34 Lean angle sensor 39 ECU engine control unit 40 Cylinder 1 left ignition coil 41 Cylinder 1 right ignition coil 42 Cylinder 2 left ignition coil 43 Cylinder 2 right ignition coil 44 Spark plug 54 Frame ground 99 Engine stop switch ...

Page 452: ...e engine con tinues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open 9 11 10 1 4 5 7 2 12 13 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 ...

Page 453: ...heck the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 148 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 147 Replace the ignition coil s 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION...

Page 454: ...n page 8 137 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 147 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 149 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 wiring Re...

Page 455: ...IGNITION SYSTEM 8 6 ...

Page 456: ... W BLACK B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B ...

Page 457: ...Battery 5 Engine ground 7 Starter relay 8 Starter motor 9 Main switch 18 Ignition fuse 21 Relay unit 22 Starting circuit cut off relay 24 Neutral switch 25 Sidestand switch 54 Frame ground 72 Clutch switch 99 Engine stop switch 100 Start switch ...

Page 458: ... 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 3 11 14 15 a WHEN THE TRANSMISSION IS IN NEUTRAL b W...

Page 459: ...eration Refer to CHECKING THE START ER MOTOR OPERATION on page 8 149 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 50 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 145 Replace the relay unit 6 Ch...

Page 460: ...tch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 137 The start switch is faulty Replace the right handlebar switch 14 Check the entire starting system wiring Refer to CIRCUIT D...

Page 461: ...ELECTRIC STARTING SYSTEM 8 12 ...

Page 462: ...B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 L...

Page 463: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 3 Main fuse 4 Battery ...

Page 464: ...ry Refer to CHECKING AND CHARGING THE BATTERY on page 8 142 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 150 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 150 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAG...

Page 465: ...CHARGING SYSTEM 8 16 ...

Page 466: ...B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 L...

Page 467: ...h 13 Headlight fuse 18 Ignition fuse 39 ECU engine control unit 54 Frame ground 60 Multi function meter 63 High beam indicator light 67 Meter light 70 Headlight relay 73 Pass switch 74 Dimmer switch 84 Headlight 87 License plate light 89 Tail brake light 93 Taillight fuse ...

Page 468: ...n and tail light Refer to CHECKING THE FUS ES on page 8 141 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 142 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 137 The...

Page 469: ... 8 20 NG OK 8 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 meter assembly head light assembly or tail brake light ...

Page 470: ... B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 ...

Page 471: ...warning light 58 Neutral indicator light 60 Multi function meter 62 Coolant temperature warning light 64 Left turn signal indicator light 65 Right turn signal indicator light 69 Turn signal hazard relay 75 Horn switch 76 Hazard switch 77 Turn signal switch 78 Horn 79 Oil level switch 80 Front right turn signal light 81 Front left turn signal light 82 Rear right turn signal light 83 Rear left turn ...

Page 472: ...llight Refer to CHECKING THE FUS ES on page 8 141 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 142 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Pro...

Page 473: ...e the 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 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 140 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE ...

Page 474: ...ace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 147 Replace the relay unit 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 meter assembly 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the oil level switch 2 Chec...

Page 475: ...page 8 21 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 152 Replace the coolant temperature sensor 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 ECU or meter asse...

Page 476: ... L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 L2...

Page 477: ...8 3 Main fuse 4 Battery 5 Engine ground 9 Main switch 16 Radiator fan motor fuse 18 Ignition fuse 32 Coolant temperature sensor 39 ECU engine control unit 54 Frame ground 90 Radiator fan motor 91 Radiator fan motor relay ...

Page 478: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 142 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 152 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING T...

Page 479: ...COOLING SYSTEM 8 30 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or repair the cooling sys tem wiring Replace the ECU ...

Page 480: ...BLACK B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W...

Page 481: ...position sensor 36 Throttle position sensor 37 Accelerator position sensor lead shield 38 Throttle position sensor lead shield 39 ECU engine control unit 40 Cylinder 1 left ignition coil 41 Cylinder 1 right ignition coil 42 Cylinder 2 left ignition coil 43 Cylinder 2 right ignition coil 44 Spark plug 45 Injector 1 46 Injector 2 47 Throttle servo motor 48 Front wheel sensor 49 Rear wheel sensor 50 ...

Page 482: ...witch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been set to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal ...

Page 483: ...he following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 36 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine EAS30610 DIAGNOSTIC MODE Setting the diagnostic mode 1 Turn the main switch to OFF 2 Disconnect th...

Page 484: ...ically decrease the diagnostic code numbers To increase the selected diagnostic code number press the left set button Press the left set button for 1 second or more to automatically increase the diagnostic code numbers 6 Check the operation of the sensor or actuator Sensor operation The data representing the operating conditions of the sensor appears on the odometer LCD Actuator operation Set the ...

Page 485: ...iagnostic code No Meter display Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of crankshaft po sition sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair rep...

Page 486: ...itch to and then operate the throttle while pushing the start switch If the display value changes the performance is OK Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of intake air pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition...

Page 487: ...Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 1000 m above sea level Ap prox 90 kPa 2000 m above sea level Ap prox 80 kPa 3000 m above sea level Ap prox 70 kPa When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Replace the intake air pres sure sensor Refer to CHECKING T...

Page 488: ...No d 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 1000 m above sea level Ap prox 90 kPa 2000 m above sea level Ap prox 80 kPa 3000 m above sea level Ap prox 70 kPa When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Replace the intake air pres ...

Page 489: ...nt or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between throttle position sensor coupler and ECU couple...

Page 490: ...ion in ECU Replace the ECU Fault code No 19 Item Sidestand switch a break or disconnection of the black red lead of the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No d 20 Meter display Sidestand switch on sidestand retracted oFF sidestand extended Procedure Extend and retract the sidestand with the transmission in gear Item Probable cause of mal...

Page 491: ...re harness A break or disconnection of the black red lead of the ECU is detected Set the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective sidestand switch Execute the diagnostic mode Code No d 20 Shift the transmission into gear Stand retracted on Stand extended oFF Replace i...

Page 492: ...ue Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of coolant temperature sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5...

Page 493: ...tween intake air tempera ture sensor coupler and ECU coupler black blue black blue brown white brown white Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of intake air temperature sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Set the main switch...

Page 494: ...n of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Start the engine warm it up and then race it Execute the diagnostic mode Code No d 63 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Wire h...

Page 495: ... Confirmation of service completion 1 The vehicle has overturned Raise the vehicle upright Set the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Set the main switch to ON then to OFF and then ba...

Page 496: ... coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short c...

Page 497: ...yed Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Start the engine and let it idle for approximately 5 second...

Page 498: ...imes Connect an ignition checker Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of cylinder 2 left ignition coil coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace th...

Page 499: ... 6 6 Malfunction in ECU Replace the ECU Fault code No 36 Item Cylinder 2 right ignition coil open or short circuit detected in the primary lead of the cylinder 2 right 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 Actuation Actuates the cylinder 2 right igniti...

Page 500: ...number is dis played Go to item 5 5 Defective cylinder 2 right ig nition coil Execute the diagnostic mode Code No d 33 Measure the primary coil re sistance of the cylinder 2 right ignition coil Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 147 Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number...

Page 501: ...istance is not 12 Ω replace the injector Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly ...

Page 502: ...ition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the main harness or lean angle sensor sub wire harness Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Main harness and or lean...

Page 503: ...d check Maintenance job Confirmation of service completion 1 Connection of rear wheel sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Execute the diagnostic mode Code No d 07 Rotate the rear wheel by ha...

Page 504: ... mode Code No d 07 Rotate the rear wheel by hand and check that the indi cated value increases Value increases Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h The fault code can also be deleted by activating the di agnostic mode and selecting diagnostic code number d 63 Value does not increase Go to item 4 4 Wire harness continuity Open or short circu...

Page 505: ...ode No 42 Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 21 Meter display Neutral on When the transmission is in neutral oFF When the transmission is in gear or the clutch lever re l...

Page 506: ...arness and or neutral switch sub wire harness con tinuity Open or short circuit Re place the wire harness and or neutral switch sub wire harness sky blue sky blue Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Defective neutral switch Check the neut...

Page 507: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h Fault code number is not dis played Service is finished Fault code number is dis...

Page 508: ...ith the meter display value If the actu ally measured battery voltage is low recharge the battery d 50 Actuation Actuates the main relay five times at one second intervals Illuminates the engine trouble warning light Procedure Check that the main relay is actuated five times by listening for the operating sound Item Probable cause of mal function and check Maintenance job Confirmation of service c...

Page 509: ...r is dis played Go to item 4 4 Malfunction or open circuit in main relay Execute the diagnostic mode Code No d 50 No operation sound of fuel injection system relay is heard Replace the relay unit Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Malfunction or open circuit in main relay Execute the diagnostic mode Code ...

Page 510: ...and ON again Replace the ECU Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Repeat the proce dure in item 1 If the same number is indicated perform the procedure in item 4 3 02 is indicated in Diagnos tic mode Code No d 60 EEP ROM data error for ad justment of CO concentration of cylinder 2 Change the CO concentra tion of cylinder ...

Page 511: ... number might not appear on the meter Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Malfunction in ECU Replace the ECU TIP Do not perform this proce dure with the main switch turned to ON Set the main switch to ON Check that the f...

Page 512: ...nect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between accelerat...

Page 513: ...alfunction detected Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of throttle servo motor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins ...

Page 514: ...to item 6 6 Defective throttle bodies Check the throttle bodies Refer to CHECKING THE THROTTLE SERVO MO TOR on page 8 155 Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 7 7 Malfunction in ECU Replace the ECU Fault code No 68 Item O2 sensor 2 no normal signals are received from the O2 sen sor 2 Fail safe system Able to st...

Page 515: ...shed Fault code number is dis played Go to item 4 4 Wire harness continuity Open or short circuit Re place the wire harness Between O2 sensor coupler and ECU coupler red white red white black green black green black blue black blue gray green gray green Start the engine warm it up and then race it Execute the diagnostic mode Code No d 63 Fault code number is not dis played Service is finished Faul...

Page 516: ...following pro cedure Rotate the front wheel by hand and check that the indi cated value increases Value increases Proceed to item 9 and delete the fault code Value does not increase Perform the procedure in item 2 2 Connection of front wheel sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pin...

Page 517: ...epair replace the wire harness or sub wire harness Execute the diagnostic mode Code No d 16 Rotate the front wheel by hand and check that the indi cated value increases Value increases Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h The fault code can also be deleted by activating the di agnostic mode and selecting diagnostic code number d 63 Value do...

Page 518: ...lue does not increase Go to item 7 7 Malfunction in ECU Replace the ECU Execute the diagnostic mode Code No d 16 Rotate the front wheel by hand and check that the indi cated value increases Value increases Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h The fault code can also be deleted by activating the di agnostic mode and selecting diagnostic code...

Page 519: ...ayed Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness yellow blue yellow blue Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Abnormal meter unit opera tion Replace the meter assembly Set the main switch to ON Fault code number i...

Page 520: ...Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness yellow blue yellow blue Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Abnormal meter unit opera tion Replace the meter assembly Set the main switch to ON Fault code number is not...

Page 521: ... played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness yellow blue yellow blue Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Abnormal meter unit opera tion Replace the meter assembly Set the main switch to ON Fault code numbe...

Page 522: ...lt code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness yellow blue yellow blue Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Abnormal meter unit opera tion Replace the meter assembly Set the main switch to ON Fault code number is not dis played Service is ...

Page 523: ...tions 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 24 42 68 69 No malfunction code 00 Malfunction code exists 24 42 68 69 Fault code number If more than one malfunc tion is detected...

Page 524: ... B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2 ...

Page 525: ...M 8 76 3 Main fuse 4 Battery 5 Engine ground 9 Main switch 10 Fuel injection system fuse 18 Ignition fuse 21 Relay unit 23 Fuel pump relay 26 Fuel pump 39 ECU engine control unit 54 Frame ground 99 Engine stop switch ...

Page 526: ...nals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 137 The engine stop switch is faulty Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 145 Replace the relay unit 6 ...

Page 527: ...FUEL PUMP SYSTEM 8 78 ...

Page 528: ...K B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L B L W2 B2...

Page 529: ...e 4 Battery 5 Engine ground 9 Main switch 12 Backup fuse odometer clock and immobilizer system 18 Ignition fuse 20 Immobilizer unit 39 ECU engine control unit 54 Frame ground 56 Immobilizer system indicator light 60 Multi function meter ...

Page 530: ...ering key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a sa...

Page 531: ...tandby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Acc...

Page 532: ...ch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert th...

Page 533: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 534: ...an the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 137 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 79 Properly connect or repair the immobilizer system wiring Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT C...

Page 535: ...nit mal function 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure Th...

Page 536: ...IMMOBILIZER SYSTEM 8 87 a Light on b Light off ...

Page 537: ...IMMOBILIZER SYSTEM 8 88 ...

Page 538: ...Br W BLACK B L W BLACK W BLACK L B B L BLACK W L W L Br Y BROWN NEUTRAL SWITCH SUB WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A WIRE HARNESS WIRE HARNESS W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B W B W W1 B1 L ...

Page 539: ...ting circuit cut off relay 39 ECU engine control unit 48 Front wheel sensor 49 Rear wheel sensor 50 Front wheel sensor lead shield 51 Rear wheel sensor lead shield 52 ABS ECU electronic control unit 53 ABS test coupler 54 Frame ground 68 ABS warning light 88 Rear brake light switch 89 Tail brake light 92 Signaling system fuse 98 Front brake light switch 99 Engine stop switch 100 Start switch ...

Page 540: ... 4 5 1 ABS warning light 2 Front wheel sensor rotor 3 Front wheel sensor 4 Right front brake caliper 5 Left front brake caliper 6 ABS ECU fuse 7 ABS solenoid fuse 8 Rear wheel sensor rotor 9 Rear wheel sensor 10 Rear brake caliper 11 ABS test coupler 12 Hydraulic unit assembly 13 ABS motor fuse ...

Page 541: ...ABS ANTI LOCK BRAKE SYSTEM 8 92 ...

Page 542: ...AS27750 ABS COUPLER LOCATION CHART R B Y W L R W B Br G Y R B B Br L W R W L W R R W R R B L W L B Dg Y B L L W Lg B Sb W W R G R W L R Br W B W B B Sb W R Lg W L B W W L B W W G Dg Y L Ch B W G R Lg R W Sb W R G Y GRAY 1 2 3 4 5 6 7 8 ...

Page 543: ... BRAKE SYSTEM 8 94 1 Right handlebar switch coupler 2 Starter relay coupler 3 Main fuse coupler 4 ABS ECU coupler 5 ABS test coupler 6 Rear wheel sensor coupler 7 Front wheel sensor coupler 8 Meter assembly coupler ...

Page 544: ...livering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 131 ABS operation when the ABS warning light comes on 1 ABS is canceled and the braking reverts to normal braking Futhermore the braking performance of the unified brake system could be reduced A malfunction was detected using the ABS self diagnosis function 2 The ABS warning light comes on and then goes off when starting the ...

Page 545: ...malfunction occurs EAS27800 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA23P1018 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 of...

Page 546: ...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 using the ABS warning light flash pattern Are fault codes indicated by the ABS warning light flash pattern TIP The ABS ECU fuse is blown Th...

Page 547: ... warning light and all other indicator lights fail to come on C 2 EAS23P1049 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 MALFUNCTIONS ARE CUR...

Page 548: ...dicated fault codes 1 The ABS warning light is on C 3 2 The ABS warning light is flashing C 4 EAS23P1052 C 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON 1 Check for a short circuit to the ground between the green red terminal of the ABS ECU coupler and green red terminal of the meter assembly If there is no short circuit to the ground the wire harness is defective Properly repair or replace the wi...

Page 549: ... green ter minal 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 battery and the A...

Page 550: ...witch to ON Information for the fault codes from the ABS ECU is contained in the following table Refer to this table for troubleshooting TIP Record all of the indicated fault codes and inspect the check points Fault code table Fault code No Symptom Check point 11 25 Front wheel sensor signal is not re ceived properly Installation of the front wheel sensor Front wheel Front wheel sensor housing Fro...

Page 551: ... mo tor Battery voltage ABS motor fuse Wire harness ABS circuit Connection of the ABS ECU coupler and starter relay coupler Hydraulic unit assembly 34 Hydraulic unit ABS motor is short cir cuited Hydraulic unit assembly 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 when the battery vo...

Page 552: ...rake master cylinder pressure sensor is defective Hydraulic unit assembly 64 Rear brake master cylinder pressure sensor is defective Hydraulic unit assembly 69 Rear brake caliper pressure sensor is defective Hydraulic unit assembly 73 Difference between the rear brake master cylinder pressure and the rear brake caliper pressure is abnormal Brake fluid Hydraulic unit operation tests Rear wheel brak...

Page 553: ...erform 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 23 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor ...

Page 554: ...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 32 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 sen...

Page 555: ...e 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 23 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 nece...

Page 556: ...me 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 32 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 nece...

Page 557: ...oupler 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 Set the main switch to OFF be fore disconnecting or connecting a coupler Set 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...

Page 558: ...ntinuity 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 15 Symptom Front wheel sens...

Page 559: ... 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 Set the main switch to OFF be fore disconnecting or connecting a coupler Set the main switch to ON and chec...

Page 560: ...ontinuity 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 16 Symptom Rear wheel senso...

Page 561: ...tion and bends Refer to CHECKING THE FRONT WHEEL on page 4 23 Set 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 the surface of the sensor rotor for foreign m...

Page 562: ...g 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 33 3 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR RO...

Page 563: ...ct the coupler se curely TIP Set 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 Between ABS ECU coupler and starter relay coupler blue white blue white Between ABS ECU coupler and right handlebar switch start switch coupler white blue white blue Fault code No 31 Symptom Solenoid rel...

Page 564: ...tor 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 8 141 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 Set the main switch to O...

Page 565: ...er 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 WHEEL on page 4 23 and CHECKING THE FRONT BRAKE DISCS on page 4 44 ...

Page 566: ...from 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 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 ca...

Page 567: ...rake hose connections are reversed on the hydraulic unit brake pipe joint 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 8 131 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 hos...

Page 568: ... and check that the operation of the hydraulic unit is normal 2 Brake master cylinder and brake cali per Check that the hydraulic 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...

Page 569: ...ke hose connections are reversed on the hydraulic unit brake pipe joint 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 8 131 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...

Page 570: ...ance job Reinstatement confirmation method 1 Battery voltage Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 142 Set 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 Connections ABS ECU coupler Check the coup...

Page 571: ... then goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal Fault code No 59 Symptom Solenoid valve data is abnormal Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Hydraulic unit assembly internal mal function Replace the hydraulic unit as sembly Set the main switch to ON and check that...

Page 572: ...hen goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal Fault code No 63 Symptom Front brake master cylinder pressure sensor is defective Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Front brake master cylinder pressure sensor malfunction Replace the hydraulic unit as sembly Set the...

Page 573: ...conds 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 Fault code No 69 Symptom Rear brake caliper pressure sensor is defective Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Rear brake caliper pressure sensor malfunction Replace the hydraulic unit as sembly Set the main sw...

Page 574: ...e brake fluid reservoir for wa ter foreign materials solidifica tion and contamination Check for air in the brake lines 3 Brake lines Check the brake lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EWA23P1020 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake lines Check that the connections o...

Page 575: ...hose inlet and outlet connections are reversed on the hydraulic unit brake pipe joint the brake pedal will be pressed down to its full stroke position without responding and then it will be pushed back slowly without pulsating when the final check on page D 3 FINAL CHECK on page 8 131 is performed If the front and rear brake hose connections are reversed on the hydraulic unit brake pipe joint the ...

Page 576: ...uid in the brake fluid reservoir for wa ter foreign materials solidifica tion and contamination Check for air in the brake lines 3 Brake lines Check the brake lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EWA23P1020 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake lines Check that the conn...

Page 577: ...hose inlet and outlet connections are reversed on the hydraulic unit brake pipe joint the brake pedal will be pressed down to its full stroke position without responding and then it will be pushed back slowly without pulsating when the final check on page D 3 FINAL CHECK on page 8 131 is performed If the front and rear brake hose connections are reversed on the hydraulic unit brake pipe joint the ...

Page 578: ...ning light does not flash in 0 5 second intervals the malfunctions have not been repaired Diagnose the malfunctions using the fault codes 8 Set 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...

Page 579: ...rness a Connect the pocket tester Ω 1 to the ABS ECU coupler and right handlebar switch cou pler b Check for continuity between the ABS ECU and the start switch lead 10 Check ABS ECU voltage Out of specification Replace the right han dlebar switch Battery voltage Higher than 12 8 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe b...

Page 580: ...of the cover into the coupler EAS23P1058 D 3 FINAL CHECK Checking procedures 1 Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 27 and IN STALLING THE REAR WHEEL R...

Page 581: ...ABS ANTI LOCK BRAKE SYSTEM 8 132 ...

Page 582: ...ELECTRICAL COMPONENTS 8 133 EAS27973 ELECTRICAL COMPONENTS 5 6 8 9 4 10 11 12 13 14 15 16 17 18 7 1 3 2 ...

Page 583: ... motor 6 Throttle position sensor 7 Accelerator position sensor 8 Intake air pressure sensor 9 Fuel pump 10 Rear brake light switch 11 Sidestand switch 12 Oil level switch 13 Cylinder 1 left ignition coil 14 Cylinder 1 right ignition coil 15 Cylinder 2 left ignition coil 16 Cylinder 2 right ignition coil 17 Radiator fan motor 18 Horn ...

Page 584: ...ELECTRICAL COMPONENTS 8 135 1 2 3 4 5 6 7 8 10 9 11 13 15 14 16 12 17 18 19 ...

Page 585: ...ay 5 Turn signal hazard relay 6 Headlight relay 7 ECU engine control unit 8 Starter relay 9 ABS motor fuse 10 Hydraulic unit assembly 11 Lean angle sensor 12 Coolant temperature sensor 13 Battery 14 Neutral switch 15 Crankshaft position sensor 16 O2 sensor 1 17 O2 sensor 2 18 Fuse box 1 19 Fuse box 2 ...

Page 586: ...S ON OFF P R Br L R Br L Br R R Y W Y G Y Br MODE Sb Dg Br W Ch Dg Br W Ch R W R B W G B W L W B Br B W R Y Y Br R BLACK B B GRAY Br Y BROWN G Y R B B Br L W R W R Y Br W W Y B Dg Br B Y Y L Y Ch BLACK L Y B Y BLACK W BLACK 6 8 7 2 5 3 4 12 15 11 14 13 9 1 10 ...

Page 587: ...switch 3 Hazard switch 4 Turn signal switch 5 Horn switch 6 Engine stop switch 7 Start switch 8 D mode switch 9 Front brake light switch 10 Rear brake light switch 11 Neutral switch 12 Sidestand switch 13 Oil level switch 14 Clutch switch 15 Main switch ...

Page 588: ...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 positi...

Page 589: ...the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from o...

Page 590: ...e continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage ra...

Page 591: ...sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged t...

Page 592: ...ull contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following ill...

Page 593: ...o charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the 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...

Page 594: ...fuel pump relay Headlight relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal R B R W L 1 4 3 W R 2 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive b...

Page 595: ... Out of specification Replace a Connect the pocket 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 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal hazard relay input voltage DC 12 V Pocket tester 90...

Page 596: ... 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 black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No ...

Page 597: ...N 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 C...

Page 598: ...rting 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 no flammable gas o...

Page 599: ...hown c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage EAS28190 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Stator coil resistance 0 112 0 168 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe whit...

Page 600: ...n circuit 1 Check Fuel meter fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for 3 seconds in a repeated cycle mal function detected in fuel sender Replace the fuel pump assembly Pocket tester 90890 03112 Analog p...

Page 601: ...sure the radiator fan motor movement EAS28261 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 4 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of ...

Page 602: ...all Throttle position sensor TIP When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 EAS29100 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle body WARNING EWA23P1028 Handle the accelerator position sensor with special care Never subject the accelerator position sen sor t...

Page 603: ...Out of specification Replace a Connect the test harness S pressure sensor 3P between the intake air pressure sensor and wire harness NOTICE ECA23P1082 Pay attention to the installing direction of the test harness S pressure sensor 3P coupler a b Connect the pocket tester DC 20 V to the test harness S pressure sensor 3P c Turn the main switch to ON d Measure the intake air pressure sensor out put v...

Page 604: ... air temperature sensor resistance 3 Install Intake air temperature sensor EAS23P1072 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors 1 Remove Fuel injector Refer to THROTTLE BODIES on page 7 5 2 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket t...

Page 605: ...ottle valves do not fully close Replace the throttle bodies a Connect two C size batteries to the throttle servo motor terminals 1 as shown NOTICE ECA23P1084 Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor Resistance 0 100 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Throttle servo ...

Page 606: ...ELECTRICAL COMPONENTS 8 157 ...

Page 607: ...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 608: ...gged or damaged fuel hose 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or d...

Page 609: ...uide 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 assembl...

Page 610: ...m 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 high Loose damper rod ...

Page 611: ...ch Headlight bulb 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 LED 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 signa...

Page 612: ...ht 62 Coolant temperature warning light 63 High beam indicator light 64 Left turn signal indicator light 65 Right turn signal indicator light 66 Traction control system indica tor light 67 Meter light 68 ABS warning light 69 Turn signal hazard relay 70 Headlight relay 71 Left handlebar switch 72 Clutch switch 73 Pass switch 74 Dimmer switch 75 Horn switch 76 Hazard switch 77 Turn signal switch 78 ...

Page 613: ......

Page 614: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 615: ...LACK B2 L2 W BLACK R B R L GRAY G B R L GRAY Sb Sb Br R BLACK Br W BLACK B L WIRE HARNESS NEUTRAL SWITCH SUB WIRE HARNESS WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A W1 W2 W3 W1 W2 W3 R R R R2 R R B B B B B B W B R B R R R W2 Br G Br Br W R G R R W R W L W Br L Br L Br L Br R Br B L R Br R W Dg Br R Br L Lg R W Sb W Y L B L Gy Gy B L1 P W B L B L B L G W Br W L Y G B L B L2 B...

Page 616: ...REEN GRAY GRAY GRAY BLACK DARK BLUE BLACK BLACK BLACK GRAY GRAY BLACK BLACK WIRE HARNESS NEUTRAL SWITCH SUB WIRE HARNESS WIRE HARNESS LEAN ANGLE SENSOR SUB WIRE HARNESS ON OFF P MODE B A A A A A B BLACK 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 37 38 39 40 41 42 43 44 44 44 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66...

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Yamaha XT1200Z(Z) 2010, Service Manual

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