Yamaha XV19CTMWC Service Manual Download Page 279

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CLUTCH

5-67

• Clutch master cylinder reservoir diaphragm

Damage/wear

→

Replace.

4. Check:

• Clutch hose

Cracks/damage/wear

→

Replace.

EAS25300

ASSEMBLING THE CLUTCH MASTER
CYLINDER

WARNING

EW1D71010

• 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.

EAS25310

INSTALLING THE CLUTCH MASTER
CYLINDER

1. Install:

• Clutch master cylinder “1”
• Clutch master cylinder holder “2”

NOTE:

• Align the end of the clutch lever holder with the

punch mark “a” on the handlebar.

• First, tighten the rear bolt, then the front bolt.

2. Install:

• Copper washers
• Clutch hose “1”
• Clutch hose union bolt “2”

WARNING

EW1D71002

Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-45.

NOTE:

• Install the clutch hose at 5–25° “a” angle to the

clutch master cylinder as shown in the illustra-
tion.

• While holding the clutch hose, tighten the

union bolt.

• Turn the handlebar to the left and right to make

sure the clutch hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.

3. Fill:

• Clutch master cylinder reservoir

(with the specified amount of the recom-
mended clutch fluid)

WARNING

EWA13370

• Use only the designated clutch fluid. Other

clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.

• Refill with the same type of clutch fluid that

is already 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.

CAUTION:

ECA13420

Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.

Recommended clutch fluid

Brake fluid DOT 4

Clutch master cylinder holder
bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

New

Recommended clutch fluid

Brake fluid DOT 4

Summary of Contents for XV19CTMWC

Page 1: ...Manuals have been CycleHippied Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data If you obtained this manual from a source other than CycleHippie It may not have been properly CycleHippied Go to CycleHippie eBay Store ...

Page 2: ...SERVICE MANUAL XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C LIT 11616 20 40 1D7 28197 11 ...

Page 3: ...W C SERVICE MANUAL 2006 by Yamaha Motor Corporation U S A First edition July 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 20 40 ...

Page 4: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable N...

Page 5: ...age 1 Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruc...

Page 6: ... 14 15 16 LT New T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part ...

Page 7: ......

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

Page 9: ......

Page 10: ...OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 11: ...LE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the rider seat This information will be needed to order spare parts 1 1 ...

Page 12: ... becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume accord...

Page 13: ...iming are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is ...

Page 14: ...n the fuel reserve a clock a self diagnosis device a brightness control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET switches except for setting the brightness control mode To switch the odometer the tripmeters and the fuel reserve tripmeter displays between kilo meters and miles press the SELECT switch for at least two seconds For USA and Califor nia only Speedometer ...

Page 15: ... The fuel gauge does not indicate the correct fuel level for the first 5 km h 3 mi h after refu eling Odometer tripmeter and clock modes Push the SELECT switch to switch the display between the odometer mode ODO the tripme ter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO If the fuel level warning light comes on the odometer display will automaticall...

Page 16: ...ed as soon as possible in order to avoid engine damage Brightness control mode The brightness can be adjusted for the following the multi function meter unit panel item num ber 1 the LCD item number 2 the speedometer tachometer and the fuel gauge needles item number 3 Select the brightness control mode as follows 1 Turn the key to OFF 2 Push and hold the SELECT switch 3 Turn the key to ON and then...

Page 17: ...URES 1 7 7 Push the SELECT switch The odometer tripmeter clock display will re turn to the prior mode 1 Speedometer needle 2 Tachometer needle 3 Fuel gauge needle 4 Item number 5 Brightness level 4 2 3 1 5 ...

Page 18: ... 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 19: ...ease Oil bearings liberally when installing if appropri ate CAUTION 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 o...

Page 20: ...al times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at...

Page 21: ...st provided below to avoid any mistakes NOTE 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 10 5 79 7 73 7 74 7 75 7 79 7 80 7 81 7 82 7 83 7 84 7 85 7 86 7 87 7 88 7 89 7 90 7 91 Thickness gauge 90890 03180 Feeler gauge set YU 2...

Page 22: ...wrench 90890 01403 Spanner wrench YU 33975 3 26 4 71 Damper rod holder 90890 01460 4 64 4 66 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 64 4 66 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 66 4 67 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 12 Valve spring compressor 90890 04019 YM 04019 5 39 5 44 Tool name Tool No Illustra...

Page 23: ...uide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 40 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 46 Universal clutch holder 90890 04086 YM 91042 5 60 5 65 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 60 5 64 5 74 5 75 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 66 5 76 5 93 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 24: ...e set 90890 06756 6 12 Pressure gauge 90890 03153 6 12 Fuel pressure adapter 90890 03176 YM 03176 6 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 6 12 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 83 Tool name Tool No Illustration Reference pages ...

Page 25: ...SPECIAL TOOLS 1 15 ...

Page 26: ... 13 TIGHTENING 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 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 CABLE ROUTING 2 45 ...

Page 27: ...V19CTMW 4P14 USA XV19CTMW 4P16 CDN XV19CTMWC 4P15 California Dimensions Overall length 2580 mm 101 6 in Overall width 1100 mm 43 3 in Overall height XV19S C XV19 C XV19M C 1100 mm 43 3 in XV19CTS C XV19CT C XV19CTM C 1515 mm 59 6 in Seat height 735 mm 28 9 in Wheelbase 1715 mm 67 5 in Ground clearance 155 mm 6 10 in Minimum turning radius 3480 mm 137 0 in Weight With oil and fuel XV19S C XV19 C XV...

Page 28: ...t oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt With oil filter cartridge replacement 4 90 L 5 18 US qt 4 31 Imp qt Oil pressure hot 60 0 kPa 900 r min 8 7 psi 900 r min 0 60 kgf cm 900 r min Transfer gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity disassembled 0 60 L 0 63 US qt 0 53 Imp qt Quantity 0 55 L 0 58 US qt 0 48 Imp qt Oil filter Oil filter type Cartridge paper Oil...

Page 29: ...25 000 25 021 mm 0 9843 0 9851 in Camshaft journal diameter crankcase side 24 957 24 980 mm 0 9826 0 9835 in Camshaft to crankcase clearance 0 020 0 064 mm 0 0008 0 0025 in Camshaft cover hole inside diameter 28 000 28 021 mm 1 1024 1 1032 in Camshaft journal diameter camshaft cover side 27 957 27 980 mm 1 1007 1 1016 in Camshaft to camshaft cover clearance 0 020 0 064 mm 0 0008 0 0025 in Camshaft...

Page 30: ...90 36 10 mm 1 4134 1 4213 in Valve head diameter A exhaust 30 90 31 10 mm 1 2165 1 2244 in Valve seat width C intake 1 10 1 30 mm 0 0433 0 0512 in Limit 2 0 mm 0 08 in Valve seat width C exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 2 0 mm 0 08 in Valve margin thickness D intake 1 15 1 45 mm 0 0453 0 0571 in Limit 0 4 mm 0 02 in Valve margin thickness D exhaust 1 15 1 45 mm 0 0453 0 0571 in Limit 0 ...

Page 31: ... K1 exhaust 16 58 N mm 94 67 lb in 1 69 kgf mm Spring rate K2 exhaust 21 98 N mm 125 51 lb in 2 24 kgf mm Installed compression spring force intake 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Installed compression spring force exhaust 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Spring tilt intake 2 5 2 0 mm Spring tilt exhaust 2 5 2 0 mm Winding direction intake Clockwise Winding direction e...

Page 32: ... 0 9073 in Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Limit 0 074 mm 0 00291 in Piston ring Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 55 mm 0 0217 in Ring side clearance 0 030 0 080 mm 0 0012 0 0032 i...

Page 33: ... 0012 0 0024 in Limit 0 10 mm 0 0039 in Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Operation Left hand operation Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in Plate quantity 10 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 1 pcs Clutch plate thickness 1 90 2 10 mm 0 0...

Page 34: ...ir filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 1D7 MITSUBISHI Maximum consumption amperage 5 5 A Output pressure 441 0 637 0 kPa 63 9 92 4 psi 4 41 6 37 kgf cm Fuel injection Model quantity INP 101 2 Manufacturer NIPPON INJECTOR Throttle body Type quantity AC43 2 Manufacturer MIKUNI ID mark XV19M XV19S XV19 XV19CTM XV19CTS XV19CT 1D71 00 XV19MC XV19SC ...

Page 35: ...IFICATIONS 2 9 Idling condition Engine idling speed 850 950 r min Intake vacuum 31 3 35 3 kPa 9 3 10 4 inHg 235 265 mmHg Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 4 0 6 0 mm 0 16 0 24 in ...

Page 36: ... in Front tire Type Tubeless Size 130 70R18M C 63H Manufacturer model DUNLOP D251F Manufacturer model BRIDGESTONE G851 RADIAL G Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 190 60R17M C 78H Manufacturer model DUNLOP D251 Manufacturer model BRIDGESTONE G850 RADIAL G Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 k...

Page 37: ... mm 0 22 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 41 30 mm 1 63 in Recommended fluid DOT 4 Steering Steering bearing type Taper roller bearing Lock to lock angle left 35 0 L...

Page 38: ...76 50 N mm 1007 82 lb in 18 00 kgf mm Spring stroke K1 0 0 50 0 mm 0 00 1 97 in Optional spring available No Enclosed gas air pressure STD 0 98 MPa 139 4 psi 9 8 kgf cm Spring preload adjusting positions Installed spring length Minimum 162 0 mm 6 38 in Standard XV19S C XV19 C XV19M C 171 0 mm 6 73 in XV19CTS C XV19CT C XV19CTM C 165 0 mm 6 50 in Maximum 171 0 mm 6 73 in Swingarm Swingarm end free ...

Page 39: ...neto Model manufacturer F4T38971 MITSUBISHI Standard output 14 0 V 32 0 A 5000 r min Stator coil resistance 0 112 0 168 Ω Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN No load regulated voltage 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GS YUASA Ten hour rate...

Page 40: ...in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Eddy Quantity 2 pcs Model manufacturer YP 12 NIKKO Maximum amperage 2 0 A Coil resistance 0 94 0 98 Ω Performance 95 115 dB 2m Turn signal relay Relay type Semi transistor Model manufacturer FB246H DENSO Built in self canceling device Yes Turn signal ...

Page 41: ...esistance at 100 C 898 4 1098 0 Ω Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Auxiliary DC connector fuse 3 0 A ECU fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 10 0 A Reserve fuse 25 0 A Reserve fuse 20 0 A Reserve fuse 15 0 A Reserve fuse 10 0 A Reserve fuse 3 0 A ...

Page 42: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 43: ... 7 2 ft lb Left balancer weight bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Left balancer idle gear shaft bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Camshaft driven gear bolt M10 1 60 Nm 6 0 m kg 43 ft lb Camshaft drive gear bolt M10 1 60 Nm 6 0 m kg 43 ft lb Front cylinder camshaft gear bolt M10 1 40 Nm 4 0 m kg 29 ft lb Locknut rocker arm adjusting screw M7 4 20 Nm 2 0 m kg 14 ft lb Valve lifter case bolt M6 4 1...

Page 44: ... Locknut EXUP cable M6 2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear exhaust pipe joint cover bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Muffler and muffler bracket bolt M8 3 29 Nm 2 9 m kg 21 ft lb Muffler bracket and frame bolt M10 2 53 Nm 5 3 m kg 38 ft lb O2 sensor M18 1 44 Nm 4 4 m kg 32 ft lb Crankcase stud bolt M12 8 See NOTE Crankcase bolt M6 21 10 Nm 1 0...

Page 45: ...arter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Primary drive gear bolt M12 1 100 Nm 10 0 m kg 72 ft lb Clutch boss nut M20 1 105 Nm 10 5 m kg 75 ft lb Stake Clutch spring plate retainer bolt M6 6 8 Nm 0 8 m kg 5 8 ft lb Bleed screw clutch release cylin der M8 1 6 Nm 0 6 m kg 4 3 ft lb Clutch release cylinder bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Drive axle bearing retainer screw M8 2 20 Nm 2 0 m kg 1...

Page 46: ... Nm 1 0 m kg 7 2 ft lb Oil tank bracket bolt M8 2 28 Nm 2 8 m kg 20 ft lb Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stopper lever bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor screw M6 2 10 Nm 1 0 m kg 7 2 ft lb Neutral switch screw M6 2 4 Nm 0 4 m kg 2 9 ft lb Stator coil screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Neutral switch lead clamp screw M6 1 10 Nm 1 0 m kg 7 2...

Page 47: ...TIGHTENING TORQUES 2 21 Cylinder head tightening sequence 3 1 2 4 A B 3 1 2 4 A Front cylinder B Rear cylinder ...

Page 48: ...ide M12 1 105 Nm 10 5 m kg 75 ft lb Engine bracket nut front upper side M10 4 53 Nm 5 3 m kg 38 ft lb Engine cross member bracket bolt M10 2 30 Nm 3 0 m kg 22 ft lb Engine bracket nut left rear low er side M10 3 58 Nm 5 8 m kg 42 ft lb Engine bracket bolt right rear lower side M10 2 53 Nm 5 3 m kg 38 ft lb Transfer gear case bracket and transfer gear case bolt M10 2 63 Nm 6 3 m kg 45 ft lb Transfe...

Page 49: ...htening torque M30 1 18 Nm 1 8 m kg 13 ft lb See NOTE Hose guide and lower handlebar holder nut M10 2 32 Nm 3 2 m kg 23 ft lb Front brake master cylinder hold er bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Front brake hose union bolt front brake master cylinder side M10 2 30 Nm 3 0 m kg 22 ft lb Clutch master cylinder holder bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Grip end M16 2 23 Nm 2 3 m kg 17 ft lb Lower ha...

Page 50: ...M8 2 16 Nm 1 6 m kg 11 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose union bolt front brake caliper side M10 2 32 Nm 3 2 m kg 23 ft lb Rear brake caliper bolt M10 2 27 Nm 2 7 m kg 19 ft lb Front brake disc bolt M6 12 23 Nm 2 3 m kg 17 ft lb Rear brake disc bolt M6 6 18 Nm 1 8 m kg 13 ft lb Bleed screw front brake caliper M8 2 6 Nm 0 6 m kg 4 3 ft lb Bleed screw rear...

Page 51: ...aster cylinder bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder bracket and frame bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder cover bolt M8 2 16 Nm 1 6 m kg 11 ft lb Brake fluid reservoir and frame bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brake hose holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Shift pedal shaft bracket...

Page 52: ...b Rear shock absorber locknut M50 1 30 Nm 3 0 m kg 22 ft lb Windshield holder bracket as sembly bolt M8 4 30 Nm 3 0 m kg 22 ft lb Windshield holder nut M8 4 23 Nm 2 3 m kg 17 ft lb Windshield bracket brace nut M6 4 10 Nm 1 0 m kg 7 2 ft lb Windshield brace nut M6 6 10 Nm 1 0 m kg 7 2 ft lb Windshield lock nut M24 1 12 Nm 1 2 m kg 8 7 ft lb Windshield lock cover nut M6 1 8 Nm 0 8 m kg 5 8 ft lb Bac...

Page 53: ...r driven gear housing Flange bolts left balancer drive gear and right balancer driven gear Camshaft cam lobes and camshaft journals Flange bolt camshaft gear Valve push rod end balls Valve stems intake and exhaust Valve stem ends intake and exhaust Valve lifters Rocker arms Rocker arm shafts Camshaft front and rear cylinders Oil pump rotors inner and outer and oil pump housing Oil pump driven gear...

Page 54: ...ive pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant E LS E M E E E LS M ...

Page 55: ... moving parts Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Shift pedal pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Dowel pins rear fender stay Pivot shaft Swingarm pivoting point collar flange circumference and oil seal inner surface Rear shock absorber bushings and O rings Swinga...

Page 56: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 22 21 19 18 20 23 17 16 15 11 10 14 13 9 8 12 14 7 6 5 4 2 3 1 9 8 ...

Page 58: ...r 8 Front cylinder head cover 9 Rear cylinder head cover 10 Rear cylinder camshaft 11 Front cylinder camshaft 12 Rear valve lifter case 13 Front valve lifter case 14 Push rod 15 Crankshaft 16 Camshaft sprocket cover 17 Generator shaft 18 Generator cover 19 Left crankcase 20 Oil filter cartridge bracket 21 Oil filter cartridge 22 Right crankcase 23 Oil cooler ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS E A A B B E E D D C C A A B E D D B 2 9 3 8 1 10 4 5 6 7 8 11 4 5 ...

Page 60: ...TEM CHART AND DIAGRAMS 2 34 1 Oil tank 2 Dipstick 3 Oil pipe 2 4 Oil delivery pipe 1 5 Oil filter cartridge 6 Oil delivery pipe 2 7 Oil pipe 3 8 Oil pipe 4 9 Oil pipe 5 10 Oil strainer oil tank 11 Oil delivery pipe 3 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 D D B B D D C C A A B C C B 3 2 1 3 4 6 7 6 7 5 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Oil pipe 1 5 Crankshaft 6 Oil pipe F mark 7 Oil pipe R mark ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 A A A A 1 3 2 4 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pipe 1 2 Oil pump 3 Oil strainer crankcase 4 Joint pipe ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 A 1 2 3 4 ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil strainer crankcase 4 Oil pump A To the oil filter cartridge ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 A A A 1 5 5 1 3 2 4 B B B B ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil pipe 5 2 Transfer gear oil pump 3 Oil strainer transfer gear case 4 Middle drive shaft 5 Oil strainer oil tank A From the oil pump ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 1 2 ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Transfer gear oil pump 2 Middle driven shaft ...

Page 71: ...CABLE ROUTING 2 45 EAS20430 CABLE ROUTING C D F F C D B B C C D D F F A E A E B B 1 1 1 1 2 3 4 5 5 5 5 5 6 6 6 6 7 7 7 7 8 9 10 11 A B C E F G D ...

Page 72: ...ar switch leads Either lead can be routed on top B 70 mm 2 76 in C 5 25 D 10 30 E Fasten the rear brake light switch lead with the plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess end of the tie F Make sure that there is no slack in the rear brake light switch lead in the area shown in the illustration G Fasten the rear brake light switch lead with the...

Page 73: ...CABLE ROUTING 2 47 B B C D D E E B B G G F F E E D D A A C F F 1 1 1 1 2 2 2 2 2 3 3 4 4 5 6 6 7 8 8 9 12 G G 3 B G J H I A C D E F K L 10 11 ...

Page 74: ... the headlight leads front turn signal position light leads and accessory light lead with the holders along the side of the headlight housing E Place the headlight leads front turn signal position light leads and accessory light lead near the base of the holder F 30 mm 1 18 in G View from rear of headlight lens unit H Less than 20 mm 0 79 in Fasten the headlight lead low beam with the holder makin...

Page 75: ... E B B I F F A B C D E F G H I J K L M S 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 14 15 16 17 21 26 F F G G D D H H H H K I B B C C Z 3 3 20 23 24 25 S W V T T T AH 18 19 27 AE AD AF U AB AA AC 28 Y X 22 N P O J J 3 4 T 4 4 O Q R R R R U V Y Z AG ...

Page 76: ...front brake hose H Make sure that the wire harness is not twisted between the fuel tank and the headlight assembly I Position the cylinder 2 left and right spark plug leads sub wire harness 2 coupler and sub wire harness 4 coupler on top of the guide J Fasten the wire harness and the cylinder 2 left and right spark plug leads with a plastic locking tie making sure to install the tie just past the ...

Page 77: ...C A A B B C C D D E G G F H H F A B C D E F G H I J K L M N N O Q R U S T O Q R S V Y Z 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15 16 17 18 15 16 18 34 18 35 19 20 21 22 23 24 24 25 26 27 28 29 30 31 32 33 36 G G X W P AD AC AB AA AA 1 2 3 ...

Page 78: ...witch lead and sidestand switch lead to the inside of the frame boss N Fasten the starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead with the plastic locking tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie O Fasten the starter motor lead horn 1 lead and rear brake light switch lead with the plastic locking tie and th...

Page 79: ...CABLE ROUTING 2 53 ...

Page 80: ...ie upward and then cut off the excess end of the tie H Connect the ECU couplers and then fasten the ECU with the band I Fasten the fuel return hose fuel return pipe to sub fuel tank with the plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess end of the tie J Route the cylinder 1 intake air pressure sensor lead so that it does not protrude past the top of...

Page 81: ...CABLE ROUTING 2 55 C C B C C A A B D E C L N 1 2 3 4 4 5 5 6 6 7 7 4 5 6 7 8 8 8 9 10 11 11 11 12 14 13 15 16 17 18 19 20 21 22 26 27 A B F G H I J K L M O P Q R S T U V W X 21 23 24 25 28 H F 24 G ...

Page 82: ... Align the ends of the hose clamp with the white paint mark on the fuel return hose F Align the paint marks on the hoses with the hose joint as shown in the illustration G Fasten the fuel tank breather overflow hose to the throttle cable guide with the holder H Align the paint mark on the hose with the hose joint as shown in the illustration I Fasten the fuel tank breather overflow hose and starte...

Page 83: ...CABLE ROUTING 2 57 C C B A B A C C A B D C E F H G I J 1 2 3 4 5 4 5 6 7 8 9 10 11 12 13 11 13 14 15 16 17 18 19 20 22 7 11 11 13 13 11 21 K ...

Page 84: ...ntake air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward Face the ends of the hose clamp forward C Fasten the canister purge hose and the air filter case breather hose 2 with the hose clamp making sure to face the ends of the clamp upward for California only D Face the ends of the hose clamp to the left E Fast...

Page 85: ...CABLE ROUTING 2 59 A B B A A B B C D E F G H I J 1 2 3 4 4 5 6 7 8 8 8 9 9 9 10 10 10 11 9 10 12 13 14 15 16 17 18 19 B ...

Page 86: ...ake manifold assembly completely onto the intake manifold making sure to face the green paint mark on the hose to the left Face the ends of the hose clamp outward angled 45 forward D Install the cylinder 1 ISC idle speed control unit outlet hose hose joint to intake manifold assembly completely onto the intake manifold making sure to face the blue paint mark on the hose to the left E Face the ends...

Page 87: ...CABLE ROUTING 2 61 ...

Page 88: ...CKING THE CYLINDER HEAD BREATHER HOSE 3 17 CHECKING THE OIL TANK BREATHER HOSE 3 17 CHECKING THE EXHAUST SYSTEM 3 17 CHECKING THE CANISTER for California only 3 18 ADJUSTING THE EXUP CABLES 3 18 CHASSIS 3 20 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 20 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE REAR BRAKE PADS 3 21 CHECKING THE FRONT BRAKE HOSES 3 21 CHECKING THE REA...

Page 89: ...ELECTRICAL SYSTEM 3 31 CHECKING AND CHARGING THE BATTERY 3 31 CHECKING THE FUSES 3 31 REPLACING THE HEADLIGHT BULBS 3 31 ADJUSTING THE HEADLIGHT BEAMS 3 32 ...

Page 90: ......

Page 91: ...acks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Adjust if necessary Every 16000 mi 25000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhau...

Page 92: ...n Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leakage Replace if necessary 18 Shock absorber assembly Check operation and for oil leakage Replace if necessary 19 Rear suspension link pivots Apply lithium soap based grease lightly 20 Engine oil Change warm engine before draining 21 ...

Page 93: ...s to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylin...

Page 94: ...arance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on p...

Page 95: ... bolts do not scratch the rocker arms or other engine parts 11 Measure Valve clearance Out of specification Adjust Piston 1 TDC rear cylinder a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion and camshaft driv...

Page 96: ...learance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b with the tappet adjusting tool 4 until the specified valve clearance is obtained Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 d c b e d c Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Thickness gauge 90890 03180 ...

Page 97: ...a suitable stand 2 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1 Fuel tank Refer to FUEL TANK on page 6 1 3 Remove Cylinder 1 intake air pressure sensor brack et 1 Cylinder 2 intake air pressure sensor brack et 2 4 Disconnect Cylinder 1 intake air pressure sensor hose 1 Cylinder 2 intake air pre...

Page 98: ...een two throttle bodies should not exceed 1 33 kPa 10 mmHg 8 Stop the engine and remove the measuring equipment 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 10 Install Fuel tank Refer to FUEL TANK on page 6 1 Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 ...

Page 99: ... plug CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug clean...

Page 100: ...Timing mark accessing screw 3 4 Connect Timing light 1 Tachometer 5 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that pointer a on the clutch cover is within the firing range b on the crankshaft position sensor rotor Incorrect firing range Check the ignition system NOTE The ignition timing is not adjustab...

Page 101: ...led Do not screw the dipstick in when inspecting the oil level CAUTION ECA13380 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase 6 Start the engine warm it up for several min utes and then turn it off 7 Check the engine oil level again NOTE Before ...

Page 102: ... Replace 9 Install Engine oil drain bolt oil tank along with the gasket 10 Install Engine oil drain bolts crankcase along with the gaskets 11 Fill Oil tank with the specified amount of the recom mended engine oil NOTE Pour the engine oil in two stages First pour in 2 5 L of oil then start the engine and rev it 3 to 5 times Stop the engine and then pour in the re mainder of the specified amount Oil...

Page 103: ...e oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 95 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolts to specification EAS20840 CHECKING THE TRANSFER GEAR OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove T...

Page 104: ...er to CHECKING THE TRANSFER GEAR OIL LEVEL on page 3 13 10 Install Exhaust pipes Muffler Refer to ENGINE REMOVAL on page 5 1 EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level WARNING EWA13370 Use only the designated ...

Page 105: ...nsiderably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic clutch system a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir di aphragm c Connect a clear plastic hose 1 tig...

Page 106: ...ge 4 1 EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Air filter case Refe...

Page 107: ...r hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21060 CHECKING THE OIL TANK BREATHER HOSE 1 Remove Right side cover Refer to GENERAL CHASSIS on page 4 1 2 Check Oil tank breather hose 1 Cracks damage Replace Loose connection Connect prope...

Page 108: ...3 Install Horn 1 Refer to THROTTLE BODIES on page 6 6 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation a Turn the main switch to ON b Check that the EXUP valve operates proper ly NOTE Check that the projection a on the EXUP valve pulley contact the stopper b fully open posi tion and the stopper c fully closed position T R Front exhaust pipe nut 20...

Page 109: ...N and check that the projection c on the EXUP valve pulley contacts the stoppers fully open and fully closed positions then stops between the lines d on the cable holder 5 Install EXUP valve pulley cover EXUP cable free play at the EXUP valve pulley a 3 mm 0 12 in or less b 3 mm 0 12 in or less Turn in a Free play is increased Turn out b Free play is decreased b c a b a 1 T R EXUP valve pulley cov...

Page 110: ...icle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance CAUTION ECA13510 After adjusting the brake pedal position make sure there is no brake drag 3 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surfa...

Page 111: ...re a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal 4 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost disap peared Replace the brake pads as a set Refer to FRONT BRA...

Page 112: ...IGHT SWITCH NOTE 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 braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn th...

Page 113: ...press down the brake pedal and hold it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plast...

Page 114: ...ngine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on the sidestand and or on a suitable stand so that the rear wheel is elevated 2 Check Drive belt slack a Out of specification Adjust NOTE The level marks of the level window on the low er drive belt c...

Page 115: ... rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 WARNING EWA12800 Always use a new gasket EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Chec...

Page 116: ...d lower bearings Refer to STEERING HEAD on page 4 69 e Install the rubber washer 3 f Install the upper ring nut g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install...

Page 117: ...cknut 2 b Turn the adjusting ring 3 in direction a or b c Tighten the locknut to specification CAUTION ECA13600 Always tighten the locknut against the ad justing nut and torque it to specification EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate Direction a Spring preload is increased suspen sion is harder Directio...

Page 118: ...the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement Tire air pressure measured on cold tires Loading conditi...

Page 119: ...HE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer ca...

Page 120: ...21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension NOTE Lubricate the pivoting points and contact surfac es between the connecting rod and frame and between the swingarm and frame Recommended lubricant Lithium soap b...

Page 121: ...ight coupler 1 b Remove Headlight bulb 2 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down c Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the...

Page 122: ...roughly clean it with a cloth moistened with alcohol or lacquer thinner f Attach Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover 7 Install Headlight assembly 8 Connect Air temperature sensor coupler 9 Install Headlight cover 10 Install Windshield For XV19CTS C XV19CT C XV19CTM C Refer to GENERAL CHASSIS on page 4 1 EAS21810 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust He...

Page 123: ...ELECTRICAL SYSTEM 3 33 a b 1 ...

Page 124: ...HECKING THE REAR WHEEL 4 28 CHECKING THE REAR BRAKE CALIPER BRACKET 4 28 CHECKING THE REAR WHEEL DRIVE HUB 4 29 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 29 ASSEMBLING THE REAR WHEEL 4 29 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 29 INSTALLING THE REAR WHEEL DISC 4 29 FRONT BRAKE 4 31 INTRODUCTION 4 36 CHECKING THE FRONT BRAKE DISCS 4 36 REPLACING THE FRONT BRAKE PADS 4 37 REMOVING THE FRONT ...

Page 125: ...LEGS 4 64 DISASSEMBLING THE FRONT FORK LEGS 4 64 CHECKING THE FRONT FORK LEGS 4 65 ASSEMBLING THE FRONT FORK LEGS 4 65 INSTALLING THE FRONT FORK LEGS 4 68 STEERING HEAD 4 69 REMOVING THE LOWER BRACKET 4 71 CHECKING THE STEERING HEAD 4 71 INSTALLING THE STEERING HEAD 4 71 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 4 73 HANDLING THE REAR SHOCK ABSORBER 4 76 DISPOSING OF A REAR SHOCK ABSORBER 4 76 REM...

Page 126: ......

Page 127: ...cket left and right 2 4 Windshield brace left and right 2 5 Windshield screen 1 6 Windshield holder bracket assembly left and right 2 For installation reverse the removal proce dure 1 6 T R 23 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib 6 3 3 2 4 R 12 Nm 1 2 m kg 8 7 ft Ib R 23 Nm 2 3 m kg 17 ft Ib...

Page 128: ...vent it from falling when removing ET1D71045 ASSEMBLING THE WINDSHIELD 1 Install Windshield lock 1 NOTE Align the projection a on the lock 1 with the slot b in the windshield bracket 2 ET1D71040 INSTALLING THE WINDSHIELD 1 Install Right windshield holder bracket assembly 1 NOTE Pass the throttle cables 2 between the front fork and the right windshield holder bracket as sembly 2 Install Windshield ...

Page 129: ...GENERAL CHASSIS 4 3 c Insert the key into the windshield lock turn it counterclockwise until it stops to lock the fas tener and then remove the key 1 Lock 2 Fastener 2 1 1 ...

Page 130: ...r on the sidebags Polish the dry leather with a soft cloth and then treat with Yamaha Mink Oil or another high quality leather protectant for increased water resistance 2 Backrest assembly 1 3 Backrest upper bracket stay 1 4 Backrest pad 1 5 Backrest plate 2 6 Backrest upper bracket 1 7 Backrest lower bracket left and right 2 For installation reverse the removal proce dure LT 1 1 2 5 7 3 6 4 R 10 ...

Page 131: ...ot b in the left backrest lower bracket 2 2 Install Backrest lower brackets 1 Backrest upper bracket 2 Backrest plate NOTE Before tightening the bolts 3 to specification temporarily install the backrest lower brackets on the backrest holders making sure not to push down on the rear of the brackets The lower bolts cannot be tightened when the backrest lower brackets are installed completely ET1D710...

Page 132: ...ke sure that the lever hook 1 on each side is secure ly fit over its holder 2 WARNING EW1D71017 Both lever hooks must be securely fitted over their holder If the backrest is loose a passenger might lose balance and fall c Insert the key into the backrest lock turn it clockwise and then remove the key b a 1 2 ...

Page 133: ...ag bracket brace 1 3 Sidebag bracket left and right 2 NOTE Remove only one sidebag bracket at a time If both brackets are removed at the same time the rear fender will fall 4 O2 sensor lead guide 1 NOTE Pass the O2 sensor lead through the guide For installation reverse the removal proce dure 4 R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib LT LT 1 1 3 3 2 4 T R 23 Nm 2 3 m kg 17 ft Ib T R 2...

Page 134: ...1D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1 Check Sidebag bracket spring nut height a Out of specification Adjust 2 Check Sidebag bracket spring nuts Damage Replace Sidebag bracket spring nut height 12 0 mm 0 47 in a ...

Page 135: ...assembly 1 6 Right side cover 1 7 Left side cover 1 8 Seat lock cable assembly 1 For installation reverse the removal proce dure 1 6 2 4 5 7 8 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib T R T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT R 7 Nm 0 7 m kg 5 1 ft Ib LT ...

Page 136: ... Headlight lens unit 1 7 Front left turn signal position light coupler 1 Disconnect 8 Front right turn signal position light coupler 1 Disconnect 9 Wire harness stopper bracket 1 10 Left handlebar switch coupler 4 Disconnect 11 Right handlebar switch coupler 3 Disconnect 12 Main switch coupler 2 Disconnect 13 Headlight body 1 For installation reverse the removal proce dure 1 3 2 8 7 10 10 9 4 11 1...

Page 137: ...unit 1 3 Coupler tray 1 4 Negative terminal cover 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 Sub wire harness 1 1 Disconnect 10 Main fuse 1 11 Plastic locking tie 1 12 Fuse box 1 13 Starter relay coupler 1 Disconnect 14 Starter relay 1 15 Diode 1 1 16 Relay unit 1 13 18 17 16 15 19 14 12 19 20 8 5 6 7 2 1 3 9 10 3 11 4 ...

Page 138: ...relay 1 18 Turn signal relay 1 19 Plastic locking tie 2 20 Battery box 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks 13 18 17 16 15 19 14 12 19 20 8 5 6 7 2 1 3 9 10 3 11 4 ...

Page 139: ...r 1 intake air pressure sensor 1 6 Cylinder 1 intake air pressure sensor bracket 1 7 Cylinder 2 intake air pressure sensor coupler 1 Disconnect 8 Cylinder 2 intake air pressure sensor hose 1 Disconnect 9 Cylinder 2 intake air pressure sensor 1 10 Cylinder 2 intake air pressure sensor bracket 1 11 Cylinder head breather hose 1 Disconnect 12 Air filter case breather hose 1 1 Disconnect 13 Air filter...

Page 140: ... screw 2 Loosen 17 Air filter case 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks 15 9 7 8 14 16 11 4 3 12 13 16 5 6 1 17 2 10 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 7 ...

Page 141: ...cket 1 7 Front fender 1 8 Reflector 2 9 Reflector bracket 2 10 Front brake caliper 2 11 Front wheel axle pinch bolt 1 Loosen 12 Front wheel axle 1 13 Front wheel 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17...

Page 142: ...7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 72 Nm 7 2 m kg 52 ft Ib 4 9 10 4 4 10 2 9 11 8 8 1 3 12 7 5 6 6 6 14 14 15 1...

Page 143: ...FRONT WHEEL 4 17 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 1 3 LS LS New New ...

Page 144: ...pinch bolt 1 4 Remove Front brake calipers NOTE Do not apply the brake lever when removing the brake calipers 5 Elevate Front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated EAS21910 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent dama...

Page 145: ...1011 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake ...

Page 146: ...b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22...

Page 147: ...hose guide bracket NOTE Temporarily tighten the front fender bolts Apply locking agent LOCTITE to the threads of the front fender bolts 8 Install Front fender stay rod 1 Left front fender stay 2 Right front fender stay 3 NOTE Insert the rod into the front wheel axle from the right side of the vehicle Tighten the left front fender stay bolt front side 4 to specification while holding the rod with a...

Page 148: ...FRONT WHEEL 4 22 ...

Page 149: ...der seat Passenger seat Tool kit tray Refer to GENERAL CHASSIS on page 4 1 1 Sub wire harness 1 coupler 1 Disconnect 2 Rear fender bracket 2 3 Dowel pin 4 4 Rear fender assembly 1 For installation reverse the removal proce dure 3 1 3 3 3 4 2 2 R 23 Nm 2 3 m kg 17 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LT LT ...

Page 150: ...er 1 3 Rear brake pad 2 4 Brake pad spring 2 5 Drive belt adjusting locknut 2 Loosen 6 Drive belt adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Right drive belt puller 1 11 Left drive belt puller 1 12 Rear brake caliper bracket 1 13 Collar 1 Black T R 7 Nm 0 7 m kg 5 1 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb 12 9 4 2 4 3 13 15 7 8 6 5 10...

Page 151: ...ation reverse the removal proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb 12 9 4 2 4 3 13 15 7 8 6 5 10 14 6 5 11 1 R 16 Nm 1 6 m kg 11 ft Ib LS LS LS ...

Page 152: ... to remove Q ty Remarks 1 Rear brake disc cover 1 2 Rear brake disc 1 3 Rear wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 8 Bearing 1 9 Collar 1 10 Bearing 1 11 Rear wheel drive hub damper 6 12 Rear wheel 1 For installation reverse the removal proce dure ...

Page 153: ... 4 27 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure 6 4 3 2 1 New LS 5 ...

Page 154: ...emove the drive belt from the rear wheel pulley EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 18 EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 18 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 27 and...

Page 155: ...ONT WHEEL on page 4 19 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 19 EAS28770 INSTALLING THE REAR WHEEL DISC 1 Lub...

Page 156: ...lt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 6 Tighten Rear wheel axle nut 7 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly T R Rear wheel axle nut 150 Nm 15 0 m kg 110 ft lb T R Rear brake caliper 27 Nm 2 7 m kg 19 ft lb ...

Page 157: ...he front brake calipers 1 Brake hose holder 1 2 Reflector 1 3 Reflector bracket 1 4 Front brake caliper 1 5 Brake pad clip 2 6 Brake pad pin 1 7 Brake pad spring 1 8 Brake pad 2 9 Brake pad shim 2 For installation reverse the removal proce dure T R 40 Nm 4 0 m kg 29 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib LT T R 10 Nm 1 0 m kg 7 2 ft Ib 1 4 8 5 3 2 9 7 9 6 ...

Page 158: ...r cylinder reservoir diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Brake light switch connector 2 Disconnect 7 Brake light switch 1 8 Front brake hose union bolt 1 9 Copper washer 2 10 Front brake hose 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 For installation reverse the removal proce dure R 30 Nm 3 0 m kg 22 ft Ib LS T R 10 N...

Page 159: ...ing the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure New 1 3 2 4 LS New ...

Page 160: ...Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Brake hose holder 1 2 Front brake hose union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Reflector 1 6 Reflector bracket 1 7 Front brake caliper 1 For installation reverse the removal proce dure R 40 Nm 4 0 m kg 29 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib LT 7 3 6 5 New 3 New 4 2 1 T R 32 Nm 3 2 m kg 23 ft Ib ...

Page 161: ...y Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake caliper piston 4 7 Brake caliper piston seal 8 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 162: ...ove Front wheel Refer to FRONT WHEEL on page 4 15 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 wh...

Page 163: ... a set 2 Install Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed s...

Page 164: ...stem 1 Remove Brake hose holder 1 Front brake hose union bolt 2 Copper washers 3 Front brake hose 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW1D71001 Do not loosen the b...

Page 165: ...ts as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is...

Page 166: ...faces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys te...

Page 167: ...nd of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the rear bolt then the front bolt 2 Install Copper washers Front brake hose 1 Front 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 45 NOTE Install the brake hose at a right angle to the front brake master cy...

Page 168: ...r reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 5 Check Brake fluid level Below the minimum level mark a Add the recommended ...

Page 169: ...rake pads Order 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 spring 2 For installation reverse the removal proce dure 1 2 4 4 3 1 T R 6 Nm 0 6 m kg 4 3 ft Ib R 27 Nm 2 7 m kg 19 ft Ib LS ...

Page 170: ...m 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake master cylinder cover 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake light switch 1 11 Right rider footrest assembly 1 12 Brake rod 1 13 Locknut 1 14 Brake master cylinder bracket 1 1 10 12 15 9 6 8 13 14 11 5 2 3 4 7 R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg...

Page 171: ...val proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 10 12 15 9 6 8 13 14 11 5 2 3 4 7 R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib R 30 Nm 3 0 m kg 22 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib LT New New LS ...

Page 172: ... cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 3 4 5 6 7 New New New ...

Page 173: ...ain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure New 4 5 2 3 4 R 27 Nm 2 7 m kg 19 ft Ib LS 1 T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 174: ...mbling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston seal 2 3 Bleed screw 1 For assembly reverse the disassembly pro cedure 2 1 3 T R 6 Nm 0 6 m kg 4 3 ft Ib New ...

Page 175: ... page 4 23 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 Refer to CHECKING THE FRONT BRAKE DISCS on page 4 36 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 36 5 Adj...

Page 176: ...on page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Brake calip...

Page 177: ...ake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Copper washers Rear brake hose 2 Rear brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to ...

Page 178: ...ke fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS...

Page 179: ...wn 2 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 may result in a harmful chemical reaction leading to poor brak...

Page 180: ... Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 20 7 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 a ...

Page 181: ... cylinder assembly 1 6 Throttle cable holder 1 7 Right handlebar switch 1 8 Throttle cable 2 9 Grip end 2 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect 12 Clutch master cylinder holder 1 13 Clutch master cylinder assembly 1 14 Left handlebar switch 2 1 5 13 18 14 17 15 12 14 11 7 9 4 7 8 19 2 2 3 16 9 1 6 10 LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 28 Nm 2 8 m kg ...

Page 182: ...ation reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 5 13 18 14 17 15 12 14 11 7 9 4 7 8 19 2 2 3 16 9 1 6 10 LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib R 50 Nm 5 0 m kg 36 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib LS LS ...

Page 183: ...le cable decelerator cable 1 to the right handlebar switch 2 NOTE Rotate the right handlebar switch and screw it onto the end of the throttle cable 3 Pass the left and right handlebar switch leads through the handlebar 4 Install Handlebar 1 Upper handlebar holder 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all th...

Page 184: ...lebar switch 1 Grip end 2 NOTE Align the projection a on the right handlebar switch with the hole b in the handlebar There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Align the end of the front brake master cylinder holder with the punch mark a on the handle bar First tight...

Page 185: ...HANDLEBAR 4 59 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in ...

Page 186: ...15 1 Upper bracket cover 1 2 Upper bracket pinch bolt 4 Loosen 3 Cap bolt 1 Loosen 4 Steering stem nut 1 5 Upper bracket 1 6 Upper front fork cover 1 7 Upper front fork cover spacer 1 8 Upper front fork cover washer 1 9 Lower front fork cover nut 2 10 Lower bracket pinch bolt 2 Loosen 11 Lower front fork cover 1 1 5 6 7 8 11 3 12 9 2 10 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 115 ...

Page 187: ...ving the front fork legs Order Job Parts to remove Q ty Remarks 1 5 6 7 8 11 3 12 9 2 10 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 115 Nm 11 5 m kg 85 ft lb R 16 Nm 1 6 m kg 11 ft Ib R 19 Nm 1 9 m kg 13 ft Ib R 23 Nm 2 3 m kg 17 ft Ib LT 4 LT 2 R 10 Nm 1 0 m kg 7 2 ft Ib LT ...

Page 188: ... 1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Inner tube bushing 1 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 23 Nm 2 3 m kg 17 ft Ib R 40 Nm 4 0 m kg 29 ft Ib New New New New New New LT New ...

Page 189: ...tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 23 Nm 2 3 m kg 17 ft Ib R 40 Nm 4 0 m kg 29 ft Ib New New New New New New LT New ...

Page 190: ...in ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver CAUTION ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer NOTE While holding the damper rod with the damper rod holder 2 and T handle 3 loosen the damper rod bolt 4 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft ...

Page 191: ...k leg do not allow any foreign ma terial to enter the front fork 4 Check Cap bolt O ring Damage wear Replace EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg b...

Page 192: ...N ECA14220 Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation Recommended oil Fork oil 10WT T R Damper rod bolt 40 Nm 4 0 ...

Page 193: ...he fork spring Out of specification Correct NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 12 Install Spring 1 Spring seat 2 Spacer Cap bolt with O ring NOTE Install the spring with the smaller pitch facing up Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt Fo...

Page 194: ...he lower front fork cover nut 2 6 Tighten Steering stem nut Cap bolt Upper bracket pinch bolts NOTE Tighten the upper bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts Upper bracket cover bolts Upper bracket cover bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly T R Lower bracket pinch bolt 23 Nm 2 3 m kg 17...

Page 195: ...et and throttle cable guide 1 2 Front brake hose guide 1 3 Front brake hose joint 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Lower bracket 1 9 Upper bearing cover 1 10 Upper bearing 1 11 Lower bearing 1 12 Dust seal 1 8 1 3 2 12 11 13 13 10 9 7 6 5 4 LS LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7...

Page 196: ...oval proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 8 1 3 2 12 11 13 13 10 9 7 6 5 4 LS LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT T R 16 Nm 1 6 m kg 11 ft Ib ...

Page 197: ...move the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head...

Page 198: ...e 3 25 3 Install Front brake hose joint 1 Front brake hose guide 2 NOTE Make sure that the projection a on the lower bracket contacts the side b of the front brake hose joint 1 Align the projection c on the front brake hose guide with the hole d in the lower bracket 4 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 60 1 b a d c 2 ...

Page 199: ...osen Refer to ENGINE REMOVAL on page 5 1 1 Horn 1 coupler 1 Disconnect 2 Horn 1 1 3 Passenger footrest left and right 2 For XV19S C XV19 C XV19M C only 4 O2 sensor lead guide 1 NOTE Pass the O2 sensor lead through the guide 5 Rear brake hose guide 1 6 Self locking nut Bolt Spacer Washer 1 1 1 1 7 Pivot shaft nut Washer 1 1 8 Pivot shaft 1 9 Rear shock absorber and swingarm assembly 1 6 2 7 10 9 8 ...

Page 200: ...al proce dure Removing the rear shock absorber assembly and swingarm Order Job Parts to remove Q ty Remarks 6 2 7 10 9 8 6 T R 59 Nm 5 9 m kg 43 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib LS 3 4 3 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib LT 1 R 48 Nm 4 8 m kg 35 ft Ib LT 6 ...

Page 201: ...onnecting arm 2 6 O ring 4 7 Spacer 1 8 Bushing 4 9 Self locking nut Washer Bolt 1 2 1 10 Rear shock absorber 1 11 Relay arm 1 12 Oil seal Spacer Bearing 2 1 1 13 Oil seal Spacer Bearing 2 1 2 14 Collar Oil seal Spacer Bearing 2 2 1 2 For installation reverse the removal proce dure T R 59 Nm 5 9 m kg 43 ft Ib 2 1 9 4 5 6 6 7 6 6 5 4 12 1 LS LS 9 LS LS LS 12 LS 10 3 8 8 13 13 14 14 11 2 LS 14 14 LS...

Page 202: ...BSORBER ASSEMBLY AND SWINGARM 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Loosen Engine mounting nut rear lower side Refer to ENGINE REMOVAL on page 5 1 NOTE Because there is force being exerted on the en gine mounting bracket left a...

Page 203: ...rm Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Bushings Damage wear Replace 4 Check Spacers Collars Damage scratches Replace EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Bushing ...

Page 204: ...s b in the bushings are within the areas shown in the illus tration 5 Install Connecting arms Rear shock absorber assembly to relay arm Relay arm to the swingarm NOTE Be sure to face the FWD mark a on the relay arm 1 toward the front of the vehicle and to face the label b on the rear shock absorber 2 downward Installed depth a 4 5 mm 0 18 in Installed depth b 1 0 mm 0 04 in Installed depth c 6 0 m...

Page 205: ... it does not drop down 5 Tighten Pivot shaft nut Engine mounting nut rear lower side Connecting arm nut front side 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 T R Connecting arm to relay arm nut 59 Nm 5 9 m kg 43 ft lb T R Rear shock absorber assembly to relay arm nut 40 Nm 4 0 m kg 29 ft lb T R Relay arm to swingarm nut 59 Nm 5 9 m kg 43 ft lb Recommended lubric...

Page 206: ...cover 1 2 Lead cover 1 3 Stator coil coupler 1 Disconnect 4 Rectifier regulator coupler 1 Disconnect 5 Rectifier regulator 1 6 Drive pulley cover 1 7 Slider 2 8 Dowel pin 2 9 Transfer gear case bracket 1 10 Drive belt 1 11 Drive pulley nut 1 12 Conical spring washer 1 LT 7 8 13 12 11 10 9 6 1 2 4 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib R 53 Nm 5 3 m kg 38 ft Ib T R 10 Nm 1 0 m kg ...

Page 207: ...the drive belt and drive pulley Order Job Parts to remove Q ty Remarks LT 7 8 13 12 11 10 9 6 1 2 4 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib R 53 Nm 5 3 m kg 38 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 3 3 T R 10 Nm 1 0 m kg 7 2 ft Ib New 7 8 4 6 5 3 LT R 140 Nm 14 0 m kg 100 ft lb ...

Page 208: ...ff with clean water Then let the drive belt thoroughly dry 2 Check Drive belt CAUTION ECA14690 To protect the drive belt from damage han dle it with care The drive belt can not be bent smaller than 127 mm 5 in a The removed drive belt can not be twisted inside out 3 Check Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pul leys as a set EAS23540 INSTALLING THE DRIVE BELT AND D...

Page 209: ...EL on page 4 23 4 Tighten Drive pulley nut NOTE When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move Stake the drive pulley nut 1 at a cutout a in the middle driven shaft 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 T R Drive pulley nut 140 Nm 14 0 m kg 100 ft lb 1 a ...

Page 210: ...ING 5 26 CHECKING THE OIL DELIVERY PIPE 5 27 INSTALLING THE CAMSHAFTS 5 27 BLEEDING A VALVE LIFTER 5 29 INSTALLING THE VALVE LIFTERS 5 30 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 31 INSTALLING THE CYLINDER HEAD COVERS 5 32 INSTALLING THE SHIFT PEDAL ASSEMBLY 5 32 CYLINDER HEADS 5 33 REMOVING THE CYLINDER HEADS 5 35 CHECKING THE CYLINDER HEADS 5 35 CHECKING THE OIL PIPE 5 35 INSTALLING THE CYLIND...

Page 211: ...TALLING THE CLUTCH MASTER CYLINDER 5 67 REMOVING THE CLUTCH RELEASE CYLINDER 5 68 CHECKING THE CLUTCH RELEASE CYLINDER 5 68 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 68 INSTALLING THE CLUTCH RELEASE CYLINDER 5 69 SHIFT SHAFT 5 70 CHECKING THE SHIFT SHAFT 5 71 CHECKING THE STOPPER LEVER 5 71 INSTALLING THE SHIFT SHAFT 5 71 GENERATOR AND STARTER CLUTCH 5 72 REMOVING THE GENERATOR 5 74 REMOVING THE ST...

Page 212: ... RELIEF VALVE 5 98 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 5 98 CHECKING THE OIL STRAINER 5 99 ASSEMBLING THE OIL PUMP 5 99 INSTALLING THE OIL PUMP 5 100 CRANKSHAFT 5 101 REMOVING THE CONNECTING RODS 5 102 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 102 INSTALLING THE CONNECTING RODS 5 105 INSTALLING THE CRANKSHAFT ASSEMBLY 5 106 TRANSMISSION 5 107 CHECKING THE SHIFT FORKS 5 111 CHECKIN...

Page 213: ...ler bracket 1 8 Muffler 1 9 Gasket 1 10 Rear exhaust pipe cover 1 11 Rear exhaust pipe 1 12 Gasket 2 13 O2 sensor 1 14 Front exhaust pipe 1 5 8 9 10 3 11 12 14 15 1 2 12 13 6 7 4 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R ...

Page 214: ...9 10 3 11 12 14 15 1 2 12 13 6 7 4 R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib New New New New New LT LT T R 44 Nm 4 4 m kg 32 ft Ib LS ...

Page 215: ...age 4 80 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 Starter motor Refer to ELECTRIC STARTER on page 5 77 1 Cylinder 1 ignition coil cover 1 2 Spark plug cap 2 3 Ignition coil connector 4 Disconnect 4 Cylinder 1 left ignition coil 1 5 Cylinder 1 right ignition coil 1 LT R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 ...

Page 216: ... heel side 1 17 Shift pedal shaft 1 18 Sidestand switch 1 19 Sidestand 1 For installation reverse the removal proce dure Removing the cylinder 1 ignition coils and sidestand Order Job Parts to remove Q ty Remarks LT R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib 48 Nm 4 8 m kg 35 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45...

Page 217: ... pin on the toe side with the mark b on the heel side 2 Install Shift pedal assembly 1 NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal 3 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 23 T R Shift pedal heel side bolt 13 Nm 1 3 m kg 9 4 ft lb T R Shift pedal bolt 18 Nm 1 8 m kg 13 ft lb a b 1 2 a 1 ...

Page 218: ... 5 Oil cooler bracket 1 6 Oil filter bolt 1 7 Oil filter bracket 1 For installation reverse the removal proce dure LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 70 Nm 7 0 m kg 50 ft lb R 17 Nm 1 7 m kg 12 ft Ib E 4 New New New New 3 2 5 LS New LT New LS New LS 4 6 1 7 New ...

Page 219: ...heck Oil cooler fins Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace NOTE Straighten any flattened fins with a thin flathead screwdriver 2 Check Oil cooler inlet hose Oil cooler outlet hose Cracks damage Replace ...

Page 220: ... 1 5 Lead holder bracket 1 6 Wire harness guide 1 7 Throttle cable guide 1 8 Starter motor lead 1 9 Horn 2 lead 1 10 Rear brake light switch lead 1 11 Sidestand switch lead 1 12 Crankshaft position sensor coupler 1 Disconnect 13 Crankshaft position sensor lead 1 14 Rectifier regulator lead 1 3 2 7 1 10 8 9 5 11 6 LT LT R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib...

Page 221: ...allation reverse the removal proce dure Disconnecting the leads Order Job Parts to remove Q ty Remarks 3 2 7 1 10 8 9 5 11 6 LT LT R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 13 4 14 12 15 ...

Page 222: ...ing nut front upper side 1 8 Engine mounting bolt front upper side 1 9 Engine cross member bracket bolt 2 10 Engine cross member bracket 1 11 Engine bracket nut front upper side 4 12 Engine bracket bolt front upper side 4 13 Engine bracket front upper side 2 R 105 Nm 10 5 m kg 75 ft lb T R 66 Nm 6 6 m kg 48 ft Ib R 30 Nm 3 0 m kg 22 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib R 53 Nm 5 3 m kg 38 ft Ib R 98 ...

Page 223: ...side 1 23 Engine mounting bolt rear lower side 1 24 Washer 1 25 Engine 1 For installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks R 105 Nm 10 5 m kg 75 ft lb T R 66 Nm 6 6 m kg 48 ft Ib R 30 Nm 3 0 m kg 22 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib R 53 Nm 5 3 m kg 38 ft Ib R 98 Nm 9 8 m kg 71 ft lb R 59 Nm 5 9 m kg 43 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib 53 N...

Page 224: ...bricate the engine mounting bolt front lower side threads and nut with engine oil Apply locking agent LOCTITE to the threads of the engine mounting bolts left upper side Do not fully tighten the bolts and nuts 2 Remove Engine mounting nut front lower side 7 3 Tighten Spacer bolt 1 NOTE Tighten the spacer bolt 1 to specification with a pivot shaft wrench When tightened the spacer bolt should be fla...

Page 225: ...BELT DRIVE on page 4 80 9 Tighten Engine bracket nut front upper side 3 Engine cross member bracket bolts 5 Engine mounting nut front upper side 7 T R Engine mounting nut rear lower side 98 Nm 9 8 m kg 71 ft lb Engine mounting nut front lower side 105 Nm 10 5 m kg 75 ft lb Engine bracket nut rear upper side 53 Nm 5 3 m kg 38 ft lb Engine mounting nut rear upper side 98 Nm 9 8 m kg 71 ft lb Engine ...

Page 226: ...Spark plug cap 4 Disconnect 2 Spark plug 4 3 Shift pedal assembly 1 4 Damper cover 1 5 Damper 1 6 Timing mark accessing screw 1 7 Crankshaft end screw 1 8 Camshaft sprocket cover 1 9 Dowel pin 2 10 Camshaft sprocket cover gasket 1 For installation reverse the removal proce dure 7 3 8 10 9 6 2 4 2 5 3 3 R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib 1 1 2 2 1 1 LS 5 New New T R 10 Nm 1 0 m ...

Page 227: ...r 1 5 Fuel outlet hose 1 Disconnect 6 Cylinder head cover bolt 8 l 40 mm 1 57 in 7 Cylinder head cover bolt 20 l 60 mm 2 36 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder head cover gasket 2 11 Dowel pin 4 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib New New 3 4 1 10 2 11 11 8 6 6 7 6 10 9 7 7 6 6 7 5 T R 7 Nm 0 7 m kg 5 1 ft Ib LT 7 7 7 6...

Page 228: ...ting 6 Pull rod 2 1 l 288 5 mm 11 358 in sky blue painting 7 Rocker arm shaft 4 8 Rocker arm 1 2 9 Rocker arm 2 2 10 Locknut 4 11 Adjusting screw 4 12 Rear rocker arm base 1 13 Front rocker arm base 1 For installation reverse the removal proce dure E E E E E E E E E 10 11 8 10 11 9 7 6 5 12 3 4 4 10 11 8 7 10 11 9 7 5 4 3 New New 1 2 13 R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 20...

Page 229: ... on page 5 45 1 Push rod cover 2 2 O ring 2 3 O ring 2 4 Seal 2 5 Rear valve lifter case 1 6 Front valve lifter case 1 7 Valve lifter 4 For installation reverse the removal proce dure 1 7 3 5 6 2 1 4 3 2 New LT LS 4 7 New New New New New New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LT LS LS E E LS LS LS ...

Page 230: ...mshaft gear 1 9 Straight key 1 10 Right balancer driven gear 1 11 Straight key 1 12 Camshaft drive gear 1 13 Right balancer drive gear 1 14 Straight key 1 15 Oil delivery pipe 1 1 16 Camshaft cover 1 17 Camshaft cover gasket 1 New R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib R 60 Nm 6 0 m kg 43 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib New New New 7 20 LS M E 2 E E 15 8 ...

Page 231: ...se the removal proce dure Removing the camshafts and right balancer Order Job Parts to remove Q ty Remarks New R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib R 60 Nm 6 0 m kg 43 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib New New New 7 20 LS M E 2 E E 15 8 9 7 6 5 4 3 1 14 10 11 13 12 16 17 18 M 19 E 21 18 ...

Page 232: ...to remove Q ty Remarks 1 Circlip 2 2 Washer 2 3 Decompression cam spring 2 4 Decompression cam 2 5 Decompression pin 2 6 Front cylinder camshaft 1 7 Rear cylinder camshaft 1 For assembly reverse the disassembly pro cedure 4 4 7 6 5 5 3 2 1 1 3 2 New New E E E E ...

Page 233: ...When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown If the marks are not aligned turn the crank shaft counterclockwise 360 degrees and re check step b 2 Remove Rocker arm bases with the rocker arms 3 R...

Page 234: ...oosen Camshaft drive gear bolt 1 Right balancer driven gear bolt 2 NOTE Place a folded copper washer 3 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Place a folded copper washer 4 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Do not damage the teeth of the right balancer drive and ri...

Page 235: ...e the camshaft Camshaft lobe dimensions Intake A 42 532 42 632 mm 1 6745 1 6784 in Limit 42 432 mm 1 6705 in Intake B 35 950 36 050 mm 1 4154 1 4193 in Limit 35 850 mm 1 4114 in Exhaust A 42 530 42 630 mm 1 6744 1 6783 in cylinder 1 42 531 42 631 mm 1 6744 1 6784 in cylinder 2 Limit 42 430 mm 1 6705 in cylinder 1 42 431 mm 1 6705 in cylinder 2 Exhaust B 35 950 36 050 mm 1 4154 1 4193 in Limit 35 8...

Page 236: ...heck Camshaft drive gears Camshaft driven gears Front cylinder camshaft gears Rear cylinder camshaft gears Chips pitting roughness wear Replace the defective part s EAS23890 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear p...

Page 237: ...k Push rod Push rod end Bends damage Replace 2 Measure Push rod runout Out of specification Replace EAS23920 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check Valve lifter Blue discoloration excessive wear pitting scratches Replace and check the lubrica tion system 2 Check Valve lifter case 1 Damage wear Replace the valve lifter case O rings 2 Damage wear Replace the O ring 3 Measure Valve...

Page 238: ... 1 projects from the camshaft Check that the decompression cam 2 and de compression pin 1 moves smoothly 2 Check Decompression cam Decompression pin Damage wear Replace ET1D71031 CHECKING THE DECOMPRESSION CAM SPRING The following procedure applies to all of the de compression cam springs 1 Measure Decompression cam spring free length a Out of specification Replace the decom pression cam spring Va...

Page 239: ...t cover bolts in stages and in a crisscross pattern 3 Install Straight keys Right balancer drive gear 1 Right balancer driven gear 2 Camshaft driven gear NOTE Cover the crankcase hole with a clean rag to prevent the straight keys from falling into the crankcase Align the punch mark a on the right balancer drive gear 1 with the punch mark b on the right balancer driven gear 2 4 Tighten Camshaft dri...

Page 240: ...pring washer 4 Washer 5 Circlip 6 NOTE Align the projection a on the washer 3 with the punch mark b on the front cylinder cam shaft gear Install the conical spring washer 4 as shown in the illustration Lubricate the front cylinder camshaft gear bolt threads with engine oil 6 Tighten Front cylinder camshaft gear bolt 1 NOTE Place a folded copper washer 2 between the teeth of the front cylinder cams...

Page 241: ...amshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gears After tightening the camshaft driven gear bolt remove the copper washer to clean the teeth of the camshaft drive and camshaft driven gears EAS24050 BLEEDING A VALVE LIFTER A valve lifter must be bled in the following cases When installing a new valve lifter When the valve lifter leaks ...

Page 242: ...th the camshaft drive gear as shown Example For bleeding the cylinder 2 intake valve lift er align mark 2 as shown i Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lift er to bleed j If necessary repeat steps h and i to bleed other valve lifters EAS24060 INSTALLING THE VALVE LIFTERS 1 Install Front valve lifter case Rear valve lifter case Valve lifters NOTE I...

Page 243: ...rods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right side of the vehicle The lengths of push rod 1 and push rod 2 are different Therefore be sure to install them in the proper position Lubricate the push rod end balls with engine oil c Install the rocker arm base bolts M6 1 and rocker arm base bolts M8 2 and 3 NOTE Tighten the rocker arm base bolts in ...

Page 244: ...hree bolts 3 cannot be installed when the cover is in place Set the bolts in the cylinder head cover and then install the cover from the right side of the vehicle Bolts 4 l 40 mm 1 57 in Bolts 5 l 60 mm 2 36 in ET1D71032 INSTALLING THE SHIFT PEDAL ASSEMBLY 1 Install Shift pedal assembly 1 NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal T R Cylinder head cover bolt 1...

Page 245: ...1 3 Engine temperature sensor 1 4 Oil pipe 1 1 5 Copper washer 4 6 Copper washer 2 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 11 Rear exhaust pipe joint cover 1 12 Rear exhaust pipe joint 1 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 R 18 Nm 1 8 m kg 13 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 66 Nm 6 6 m kg ...

Page 246: ...Remarks 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 R 18 Nm 1 8 m kg 13 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib R 20 Nm 2 0 m kg 14 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 60 Nm 6 0 m kg 43 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib New LT E New New New New New New New LT 3 ...

Page 247: ...alve seats 2 Check Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figur...

Page 248: ...olts evenly and then torque them to specification 5 Install Engine bracket right upper side Engine bracket bolts right upper side Engine mounting bolts right upper side Engine bracket left upper side Engine bracket bolts left upper side Engine mounting bolts left upper side NOTE Apply locking agent LOCTITE to the threads of the engine mounting bolts left upper side Do not fully tighten the bolts 6...

Page 249: ...ng bolt right up per side 59 Nm 5 9 m kg 43 ft lb Engine mounting bolt left upper side 66 Nm 6 6 m kg 48 ft lb LOCTITE Engine bracket bolt right upper side 53 Nm 5 3 m kg 38 ft lb Engine bracket bolt left upper side 53 Nm 5 3 m kg 38 ft lb ...

Page 250: ...edure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 33 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure 1 M E M E New New New New M M 7 3 6 2 1 7 3 6 2 1 8 8 8 7 3 6 2 7 3 6 2 1 8 4 5 ...

Page 251: ... NOTE There should be no leakage at the valve seat 1 2 Remove Valve cotters NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor set 1 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VAL...

Page 252: ...er valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 ...

Page 253: ...ing 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 b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the valve seat and valve face contacted one anoth...

Page 254: ...g results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press ...

Page 255: ... stem seal 2 with the recommended lubricant 3 Install Valve guide 1 Free length intake 46 71 mm 1 84 in Limit 44 71 mm 1 76 in Free length exhaust 46 71 mm 1 84 in Limit 44 71 mm 1 76 in Installed compression spring force intake 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Installed compression spring force exhaust 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Installed length intake 32 66 mm 1...

Page 256: ... springs with the larger pitch a facing up 4 Install Valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 0...

Page 257: ...emarks Cylinder heads Refer to CYLINDER HEADS on page 5 33 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Circlip 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 8 9 2 10 3 5 4 3 7 6 5 4 5 8 9 10 7 6 5 1 New E New E E New New New New ...

Page 258: ...g a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Meas...

Page 259: ...place the piston and piston rings as a set NOTE 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 NOTE Level the piston ring into the cylinder with the piston crown Piston Diameter D 99 960 99 975 mm 3 9354 3 9360 in b 10 mm 0 39 in from the bottom edge of the piston Piston to cylinder...

Page 260: ...earance Out of specification Replace the piston pin and piston as a set EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd ring 2 Lower oil ring rail 3 Upper oil ring rail 4 Piston ring Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 45 0 60 mm 0 01...

Page 261: ...p from falling into the crankcase 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 Cylinder 1 NOTE While compressing the piston rings ...

Page 262: ...only Fuel tank Sub fuel tank Refer to FUEL TANK on page 6 1 Left rider footrest assembly Shift rod Sidestand Refer to ENGINE REMOVAL on page 5 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 72 Drive pulley case Refer to TRANSFER GEAR CASE on page 5 81 1 Crankshaft position sensor coupler 1 Disconnect 2 Shift arm 1 3 Clutch cover 1 4 Clutch cover gasket 1 T R 12 Nm 1 2 m kg 8 7 f...

Page 263: ...pin 2 For installation reverse the removal proce dure Removing the clutch cover Order Job Parts to remove Q ty Remarks T R 12 Nm 1 2 m kg 8 7 ft Ib 5 3 4 5 2 1 R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib New 11 5 ...

Page 264: ...ty Remarks 1 Oil seal 1 2 Bearing 1 3 Clutch cover damper plate 1 4 Clutch cover damper 1 5 Crankshaft position sensor lead holder 3 6 Crankshaft position sensor 1 For installation reverse the removal proce dure 5 6 5 5 4 3 T R 10 Nm 1 0 m kg 7 2 ft Ib 1 2 New LS LT LT LT LT LT LT ...

Page 265: ... plate 9 8 Friction plate 2 9 9 Clutch boss nut 1 10 Conical spring washer 1 11 Washer 1 12 Wire circlip 1 13 Clutch plate 1 14 Friction plate 3 1 Inside diameter 135 mm 5 31 in 15 Clutch damper spring 1 16 Clutch damper spring seat 1 17 Clutch boss 1 E E 7 8 6 21 20 22 23 27 28 26 25 23 19 24 18 17 16 15 14 13 12 10 9 11 3 2 1 4 5 29 30 31 33 32 6 T R 8 Nm 0 8 m kg 5 8 ft Ib New New New New LS E ...

Page 266: ... Crankshaft position sensor rotor 1 31 Primary drive gear 1 32 Straight key 1 33 Washer 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E E 7 8 6 21 20 22 23 27 28 26 25 23 19 24 18 17 16 15 14 13 12 10 9 11 3 2 1 4 5 29 30 31 33 32 6 T R 8 Nm 0 8 m kg 5 8 ft Ib New New New New LS E LS E E T R 105 Nm 10 5 m kg 75 ft lb R 100 Nm 10 0 m kg...

Page 267: ... gear shaft 1 6 Left balancer drive gear 1 7 Straight key 1 8 Left balancer driven gear 1 9 Left balancer weight 1 1 10 Left balancer weight 2 1 11 Left balancer driven gear housing 1 12 Gasket 1 For installation reverse the removal proce dure 8 1 2 2 5 3 3 4 6 7 11 R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New E E LT LS 6 9 10 LT LS LS 12 New 3 ...

Page 268: ...reservoir diaphragm holder 1 4 Clutch master cylinder reservoir diaphragm 1 5 Clutch lever 1 6 Clutch master cylinder push rod pin 1 7 Clutch switch coupler 1 Disconnect 8 Clutch switch 1 9 Clutch hose union bolt 1 10 Copper washer 2 11 Clutch hose 1 12 Clutch master cylinder holder 1 13 Clutch master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 5 8 12 13 7 10 9 11 T R 10 Nm ...

Page 269: ...nder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure 3 4 5 6 2 1 New New LS ...

Page 270: ...15 Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For installation reverse the removal proce dure 6 3 1 4 5 2 T 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib R 19 Nm 1 9 m kg 13 ft Ib New ...

Page 271: ...ve Q ty Remarks 1 Boots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 6 Clutch release cylinder body 1 For assembly reverse the disassembly pro cedure LS LS 1 2 4 6 3 5 New 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 272: ...unless there is serious clutch chattering EAS25090 REMOVING THE PRIMARY DRIVE GEAR 1 Loosen Primary drive gear bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primary drive gear bolt ET1D71021 REMOVING THE LEFT BALANCER DRIVE GEAR 1 Loosen Left balancer drive gear bolt 1 NOTE While the holding the generator rotor 2 with the primary sheave holder 3 loosen the lef...

Page 273: ...ck 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 Damage Replace Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in Friction plate 2 thickness 2 92 3 08 mm 0 ...

Page 274: ...EAS25190 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out of specification Replace the defective part s EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive nois...

Page 275: ...t balancer driven gear 3 NOTE Make sure that the punch marks a on the left balancer driven gear are facing toward left bal ancer weight 2 2 Remove Generator rotor Refer to REMOVING THE GENERATOR on page 5 74 3 Align Mark a on the generator drive gear of the crankshaft with the mark b on the generator shaft driv en gear a Turn the crankshaft b When the front and rear pistons are near TDC align the ...

Page 276: ...ighten the left balancer drive gear bolt EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Washer Straight key Primary drive gear Crankshaft position sensor rotor 1 Spacer Primary drive gear bolt 2 CAUTION EC1D71007 The timing marks on the crankshaft position sensor rotor must face outside NOTE Lubricate the primary drive gear bolt threads with engine oil While holding the generator rotor 3 wit...

Page 277: ...al spring washer mating surfaces with engine oil Install the conical spring washer 2 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 a cutout b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates 2 1 Clutch plates Friction plate...

Page 278: ...m 1 Remove Clutch hose union bolt 1 Copper washers 2 Clutch hose 3 NOTE To collect any remaining clutch fluid place a container under the master cylinder and the end of the clutch hose ET1D71037 CHECKING THE CLUTCH MASTER CYLINDER 1 Check Clutch master cylinder Damage scratches wear Replace Clutch fluid delivery passage clutch master cylinder body Obstruction Blow out with compressed air 2 Check C...

Page 279: ...ighten the union bolt Turn the handlebar to the left and right to make sure the clutch hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Clutch master cylinder reservoir with the specified amount of the recom mended clutch fluid WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage...

Page 280: ...d carefully EAS25330 CHECKING THE CLUTCH RELEASE CYLINDER 1 Install Clutch release cylinder body Cracks damage Replace the clutch re lease cylinder 2 Check Clutch release cylinder 1 Clutch release cylinder piston 2 Rust scratches wear Replace the clutch release cylinder and clutch release cylinder piston as a set EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER WARNING EW1D71006 Before installation...

Page 281: ...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 CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a c...

Page 282: ...housing Refer to CLUTCH on page 5 50 1 Washer 3 2 Circlip 2 3 Shift shaft 1 4 Shift shaft spring 1 5 Stopper lever 1 6 Collar 1 7 Stopper lever spring 1 8 Shift shaft spring stopper 1 For installation reverse the removal proce dure E 8 1 2 1 4 3 6 5 7 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib LT LT LS New New ...

Page 283: ...ar Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Collar Stopper lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Washers Circlips Shift shaft spring 1 Shift shaft 2 NOTE Hook the end of the shift shaft spring onto the shift...

Page 284: ...E on page 4 80 Clutch pipe Refer to CLUTCH on page 5 50 1 Stator coil coupler 1 Disconnect 2 Oil delivery pipe 2 1 3 Generator cover 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder 1 7 Stator coil 1 For installation reverse the removal proce dure 5 LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib LS 3 T R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib 4 5 ...

Page 285: ...clutch idle gear shaft 1 3 Starter clutch idle gear 1 4 Generator rotor 1 5 Starter clutch 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Bearing 1 9 Bearing housing 1 For installation reverse the removal proce dure E E R 80 Nm 8 0 m kg 58 ft Ib T E T R 10 Nm 1 0 m kg 7 2 ft Ib 4 6 2 3 1 5 6 E 7 T R 24 Nm 2 4 m kg 17 ft Ib LT LT 8 9 ...

Page 286: ...ar Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the starter clutch and hold the generator rotor 2 b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage ot...

Page 287: ...the generator shaft and the generator rotor hub When installing the rotor make sure the woo druff key is properly seated in the key way of the generator shaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 NOTE While holding the generator rotor 2 with a sheave holder 3 tighten the generator rotor bolt 3 Apply Sealant onto the ...

Page 288: ...GENERATOR AND STARTER CLUTCH 5 76 Yamaha bond No 1215 90890 85505 Three Bond No 1215 ...

Page 289: ...EAS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 290: ...aring 1 3 Oil seal 1 4 Circlip 1 5 Starter motor rear cover 1 6 Brush 2 7 Brush holder along with the brushes 1 8 Brush seat along with the brushes 1 9 Bearing 1 10 Gasket 2 11 Armature assembly 1 12 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 6 2 3 5 7 1 4 LS New New New New New New 10 9 10 8 12 11 LS ...

Page 291: ...commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 5 mm 1 08 in Mica un...

Page 292: ...ve part s EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 NOTE Align the projection a on the brush holder with the slot b in the starter motor yoke 2 Install Starter motor front cover 1 NOTE Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 1 b a a b 1 ...

Page 293: ...ease cylinder Refer to CLUTCH on page 5 50 Drive pulley Refer to BELT DRIVE on page 4 80 1 Oil pipe 2 1 2 Oil pipe 4 1 3 Transfer gear case cover 1 4 Transfer gear case gasket 1 5 Dowel pin 2 6 Transfer gear oil pump assembly 1 7 Dowel pin 2 8 6 7 1 2 3 12 10 5 5 4 9 7 5 13 New New 7 E New New New New New New 11 LS LS R 10 Nm 1 0 m kg 7 2 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib R 18 Nm 1 8 m kg 13 ft Ib R 1...

Page 294: ...dle driven shaft Order Job Parts to remove Q ty Remarks 8 6 7 1 2 3 12 10 5 5 4 9 7 5 13 New New 7 E New New New New New New 11 LS LS R 10 Nm 1 0 m kg 7 2 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib R 18 Nm 1 8 m kg 13 ft Ib R 140 Nm 14 0 m kg 100 ft lb T R 40 Nm 4 0 m kg 29 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT T R 5 Nm 0 5 m ...

Page 295: ...emarks 1 Transfer gear oil pump cover 1 2 Transfer gear oil pump outer rotor 1 3 Transfer gear oil pump inner rotor 1 4 Pin 1 5 Washer 1 6 Transfer gear oil pump shaft 1 7 Transfer gear oil pump housing 1 For assembly reverse the disassembly pro cedure 5 7 6 3 2 1 6 T R 4 Nm 0 4 m kg 2 9 ft Ib E 4 ...

Page 296: ...ANK on page 6 1 1 Oil tank breather hose 1 Disconnect 2 Speed sensor 1 3 Oil tank damper 1 4 Dipstick 1 5 Dipstick joint 1 6 Drive pulley case 1 7 Dowel pin 2 8 Spacer 1 9 Transfer gear case 1 10 Dowel pin 2 For installation reverse the removal proce dure LS LS LS New New New New New 3 2 10 4 1 7 8 4 5 9 8 6 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 50 Nm 5 0 m kg 36 ft Ib...

Page 297: ...tank cover 1 3 Oil tank cover gasket 1 4 Dowel pin 2 5 Oil strainer 1 6 Oil pipe 5 1 7 Oil tank 1 For assembly reverse the disassembly pro cedure 3 2 15 4 5 6 1 7 New R 10 Nm 1 0 m kg 7 2 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New R 43 Nm 4 3 m kg 31 ft Ib LT New T R 10 Nm 1 0 m kg 7 2 ft Ib LS ...

Page 298: ...mage wear Replace the middle drive gear middle driven shaft and primary chain as a set 2 Check Primary chain Damage stiffness Replace the primary chain middle drive gear and middle driven shaft as a set EAS25490 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with engine oil EAS25500 CHECKING THE TRANSFER GEAR OIL PUMP 1 Check Transfer gear oil pump housing Transfe...

Page 299: ...mp shaft with the groove in the inner ro tor 3 Check Transfer gear oil pump operation Refer to CHECKING THE TRANSFER GEAR OIL PUMP on page 5 86 EAS25530 INSTALLING THE TRANSFER GEAR CASE 1 Install Spacer 1 NOTE Install the spacer with its groove a towards the drive pulley 2 Install Middle driven shaft 1 Middle drive gear 2 Primary chain 3 into the transfer gear case Drive pulley nut NOTE Install t...

Page 300: ...e Temporarily install the drive pulley nut onto the middle driven shaft 3 Install Conical spring washer 1 Middle drive gear nut 2 NOTE Lubricate the middle drive gear nut threads and conical spring washer mating surfaces with engine oil Install the conical spring washer 1 with the OUT mark a facing out Stake the middle drive gear nut 2 at a cutout b in the drive axle 4 Remove Drive pulley nut T R ...

Page 301: ...ER CLUTCH on page 5 72 1 Neutral switch 1 2 Oil pipe 3 1 3 Oil strainer 2 4 Oil delivery pipe 3 1 5 Engine oil pump driven gear stopper 1 6 Engine oil pump driven gear 1 7 Oil baffle plate left crankcase 1 8 Left crankcase 1 9 Dowel pin 2 New 1 11 9 4 5 6 2 5 7 3 13 8 9 10 12 T R 10 Nm 1 0 m kg 7 2 ft Ib 24 Nm 2 4 m kg 17 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg...

Page 302: ...arts to remove Q ty Remarks New 1 11 9 4 5 6 2 5 7 3 13 8 9 10 12 T R 10 Nm 1 0 m kg 7 2 ft Ib 24 Nm 2 4 m kg 17 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib 3 New T R 10 Nm 1 0 m kg 7 2 ft Ib LS New LT New New LS New New 6 LS LT LT R 43 Nm 4 3 m kg 31 ft Ib 4 LS LT 4 4 8 LT T R 10 Nm 1 0 m kg 7 2 ft Ib LS LT ...

Page 303: ...HAFT on page 5 101 Transmission Refer to TRANSMISSION on page 5 107 1 Oil baffle plate right crankcase 1 2 Bearing retainer 2 3 Bearing retainer 2 4 Oil seal 2 5 Bearing 4 For installation reverse the removal proce dure LS 4 2 1 3 3 5 5 T R 20 Nm 2 0 m kg 14 ft Ib LT New T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT R 10 Nm 1 0 m kg 7 2 ft Ib New E LT LT New E 5 5 LS ...

Page 304: ...sure the crankcase halves sepa rate evenly EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air ET1D71005 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearin...

Page 305: ... 1 Oil pipe R mark 2 Dowel pins 3 Joint pipe 4 3 Install Left crankcase onto the right crankcase NOTE Tap lightly on the left crankcase with a soft face hammer 4 Install Crankcase bolts M6 Crankcase bolts M8 NOTE Lubricate the bolt threads with engine oil Tighten each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern Tighten the bolts in numerical order refer to the numbers in th...

Page 306: ... oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair A Right crankcase B Left crankcase 4 1 5 3 6 7 2 8 A 21 20 16 15 14 19 17 18 12 10 9 22 23 13 11 24 B ...

Page 307: ...0 OIL PUMP Removing the oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Oil pump assembly 1 For installation reverse the removal proce dure 1 T R 24 Nm 2 4 m kg 17 ft Ib ...

Page 308: ...1 1 6 Oil strainer 1 7 Pin 2 8 Ball spring 1 9 Oil scavenging pump outer rotor 2 1 10 Oil scavenging pump inner rotor 2 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Relief valve spring 1 14 Relief valve 1 15 Oil feed pump outer rotor 1 16 Oil feed pump inner rotor 1 17 Pin 1 E E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 3 12 15 16 17 2 1 9 7 7 14 13 20 21 22 23 8 10 6 11 4 19 18 24 ...

Page 309: ...Ball guide 1 24 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks E E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 3 12 15 16 17 2 1 9 7 7 14 13 20 21 22 23 8 10 6 11 4 19 18 24 New New New E ...

Page 310: ...alve spring Damage wear Replace the defective part s ET1D71035 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 1 Measure Ball spring free length Relief valve spring free length Out of specification Replace the defective part s Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Oil pump housing to inner and outer rotor clearance 0 06 0 13 mm 0 0024 0 0051 ...

Page 311: ...scavenging pump inner rotor 2 15 Oil scavenging pump outer rotor 2 16 Ball spring 17 Pins 18 Oil strainer 19 Oil pump housing 1 20 Pin 21 Oil scavenging pump inner rotor 1 22 Oil scavenging pump outer rotor 1 23 Oil pump housing cover 1 24 NOTE When installing the inner rotor align the pin in the oil pump shaft with the groove in the inner ro tor Ball spring Installed compression spring force 2 23...

Page 312: ... 98 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump assembly bolt 24 Nm 2 4 m kg 17 ft lb E E 20 22 13 10 9 8 23 24 16 18 18 11 12 5 4 3 2 17 15 19 1421 6 7 1 New New New E 1 ...

Page 313: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal proce dure ...

Page 314: ...ce the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the inside of the connectin...

Page 315: ...ure f Tighten the connecting rod bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specified angle 125 135 WARNING EW1D71011 When a bolt is tightened more than the spec ified angle do not loosen and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION ...

Page 316: ...s 5 Measure Crankshaft journal diameter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside diameter a Out of specification Replace the crank case assembly NOTE Measure the inside diameter of each crankshaft journal bearing at two places P1 P2 a P1 connecting rod P crankshaft 5 2 3 brown Beari...

Page 317: ...ign the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection c on the connecting rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod bolts 1 WARN...

Page 318: ...until it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Generator shaft 1 Crankshaft assembly 2 CAUTION ECA13970 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Make sure that the generator shaft drive gear teeth and generator shaft driven gear...

Page 319: ...r Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 89 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork 1 2 4 Shift fork 2 1 5 Drive axle assembly 1 6 Main axle assembly 1 7 Spacer 1 For installation reverse the removal proce dure New 4 6 5 1 7 2 3 3 LS E E 1 E M M ...

Page 320: ...nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Collar 1 6 Toothed washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Toothed washer 1 11 4th pinion gear 1 12 Collar 1 13 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure ...

Page 321: ...ty Remarks 1 Circlip 1 2 Washer 1 3 1st wheel gear 1 4 Collar 1 5 4th wheel gear 1 6 Circlip 1 7 Toothed washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 12 5th wheel gear 1 13 Circlip 1 14 Toothed washer 1 15 2nd wheel gear 1 16 Collar 1 ...

Page 322: ...TRANSMISSION 5 110 17 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks ...

Page 323: ...place the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device a...

Page 324: ...re the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 NOTE With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with an axle spline ...

Page 325: ...shift forks should face towards the left side of the engine 2 Check Transmission Rough movement Repair NOTE Apply engine oil to each gear and bearing thor oughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 3 4 4 2 1 ...

Page 326: ...HROTTLE BODIES 6 6 REMOVING THE FUEL HOSE 6 11 CHECKING THE INJECTORS 6 11 CHECKING THE THROTTLE BODIES 6 11 CHECKING THE ROLLOVER VALVES 6 11 CHECKING THE PRESSURE REGULATOR 6 11 CHECKING THE PRESSURE REGULATOR OPERATION 6 11 ADJUSTING THE THROTTLE POSITION SENSOR 6 12 INSTALLING THE FUEL PIPE 6 12 INSTALLING THE FUEL HOSE 6 13 ISC IDLE SPEED CONTROL UNIT 6 14 CHECKING THE ISC IDLE SPEED CONTROL ...

Page 327: ... sender coupler 1 Disconnect 4 Fuel tank breather hose 1 Disconnect 5 Air vent hose fuel pump to fuel hose joint 1 Disconnect 6 Fuel tank 1 7 Fuel tank bracket rear side 1 8 Fuel tank bracket front side 1 9 Fuel sender 1 For installation reverse the removal proce dure 2 6 1 8 3 5 9 7 R 4 Nm 0 4 m kg 2 9 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm...

Page 328: ...ump coupler 1 Disconnect 2 Fuel hose connector cover 1 3 Fuel outlet hose 1 Disconnect 4 Air vent hose fuel pump to fuel hose joint 1 5 Fuel return hose fuel return pipe to sub fuel tank 1 Disconnect 6 Fuel pump bracket 1 7 Fuel pump gasket 1 8 Fuel pump 1 9 Sub fuel tank 1 For installation reverse the removal proce dure 8 9 1 3 4 5 6 7 T R 5 Nm 0 5 m kg 3 6 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib 3 New ...

Page 329: ...ant in the areas shown in the illustration c Turn the screws 1 clockwise NOTE Turn the screws until they stop d Disconnect the fuel hose fuel hose joint to fuel pump 1 and air vent hose fuel pump to fuel hose joint 2 NOTE Before removing the hoses place a few rags in the area under where they will be removed e Install the fuel hose joint cap 1 and rubber plug 2 NOTE Insert the projection on the fu...

Page 330: ...ING THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the sub fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Align the projection a on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tight ening sequence as shown 2 Connect Fuel outlet hose 3 ...

Page 331: ...t the clips a e Install the fuel hose joint caps NOTE Install the fuel hose joint caps completely onto the fuel hose joints 2 Install Meter assembly couplers Fuel sender coupler NOTE Make sure that the couplers are positioned as shown in the illustration in the following order from left to right fuel sender coupler 1 6 pin black meter assembly coupler 2 6 pin white meter assembly coupler 3 and 3 p...

Page 332: ...a only 3 Fuel tank breather hose 1 4 Canister purge hose 1 For California only 5 Rollover valve 1 1 6 Rollover valve 2 1 7 Rollover valve hose 4 8 Fuel tank breather overflow hose 1 9 Canister 1 For California only 10 Canister breather hose 1 For California only For installation reverse the removal proce dure 3 7 2 1 4 6 7 7 9 8 5 7 T R 10 Nm 1 0 m kg 7 2 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 10 ...

Page 333: ...y to pres sure regulator 1 3 Air filter case breather hose 1 1 4 Air filter case breather hose 2 1 5 Hose clamp 1 6 Pressure regulator 1 7 Fuel return hose 1 8 Fuel return pipe 1 9 Pressure regulator bracket 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 13 Nm 1 3 m kg 9 4 ft Ib 8 7 5 4 3 6 1 9 2 ...

Page 334: ...on page 5 1 1 Throttle position sensor coupler 1 Disconnect 2 Cylinder 1 intake air pressure sensor hose 1 3 Cylinder 2 intake air pressure sensor hose 1 4 Canister purge hose 1 For California only 5 Throttle cable 2 Disconnect 6 Throttle body joint clamp screw 2 Loosen 7 Throttle body 1 CAUTION EC1D71013 The throttle bodies should not be disas sembled 8 Throttle position sensor 1 For installation...

Page 335: ...let hose 1 Disconnect 4 Fuel hose intake manifold assembly to pres sure regulator 1 5 Cylinder 2 ISC idle speed control unit outlet hose 1 Disconnect 6 Cylinder 1 ISC idle speed control unit outlet hose 1 Disconnect 7 Intake manifold assembly 1 8 Gasket 2 For installation reverse the removal proce dure 2 2 2 1 8 4 7 8 5 3 6 New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 336: ... 1 Disconnect 2 Cylinder 2 injector coupler 1 Disconnect 3 Sub wire harness 2 1 4 Fuel pipe 1 5 Injector joint 1 1 6 Injector joint 2 1 7 Injector 2 For assembly reverse the disassembly pro cedure 5 7 3 1 6 7 4 R 30 Nm 3 0 m kg 22 ft Ib New New New New New New New New 2 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib ...

Page 337: ... ies as a set 2 Check Fuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with compressed air ET1D71007 CHECKING THE ROLLOVER VALVES 1 Check Rollover valve 1 1 Rollover valve 2 2 Damage faulty Replace NOTE Check that air flows smoothly only in the direc tion of the arrow shown in...

Page 338: ... Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 ET1D71008 INSTALLING THE FUEL PIPE 1 Install Fuel pipe 1 Vacuum pressure pump gauge set 90890 06756 Pressure gauge 90890 03153 Fuel pressure adapter 90890 03176...

Page 339: ...e make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose securely onto the fuel pipe or pressure regulator until a distinct click is heard To install the fuel hose onto the fuel pipe or pressure regulator slide the fuel hose connec tor cover 1 on the...

Page 340: ... 2 ISC idle speed control unit outlet hose 2 4 Cylinder 1 ISC idle speed control unit outlet hose 2 5 ISC idle speed control unit inlet hose 1 6 Cylinder 2 left ignition coil 1 7 Cylinder 2 right ignition coil 1 8 ISC idle speed control unit 1 9 ISC idle speed control unit bracket 1 For installation reverse the removal proce dure 6 7 9 3 3 5 4 4 1 8 2 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg ...

Page 341: ...ISC IDLE SPEED CONTROL UNIT 6 15 ET1D71010 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 1 Check Hoses Loose connections Connect properly Cracks damage Replace ...

Page 342: ...ARGING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING 7 15 LIGHTING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 19 SIGNALING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 23 FUEL INJECTION SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 ECU SELF DIAGNOSTIC FUNCTION 7 29 SELF DIAGNOSTIC FUNCTION TABLE 7 30 TROUBLESHOOTING METHOD 7 32 DIAGNOSTIC MODE 7 33 TROUBLESHOOTING DETAILS 7 40 FUEL PUMP SYSTEM...

Page 343: ...ITION SENSOR 7 84 CHECKING THE LEAN ANGLE SENSOR 7 84 CHECKING THE STARTER MOTOR OPERATION 7 85 CHECKING THE STATOR COIL 7 85 CHECKING THE RECTIFIER REGULATOR 7 85 CHECKING THE HORNS 7 86 CHECKING THE ENGINE TEMPERATURE SENSOR 7 87 CHECKING THE FUEL SENDER FUEL TANK 7 87 CHECKING THE FUEL SENDER FUEL PUMP 7 88 CHECKING THE FUEL LEVEL WARNING LIGHT 7 88 CHECKING THE SPEED SENSOR 7 88 CHECKING THE T...

Page 344: ......

Page 345: ... G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G B L R G R B R B R B R B R B R B C C D Y B Gy W W R B G B R W R BLACK L W R B G R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy Gy W BLACK R L B L Gy G Gy W B B W L R L Gy W Gy G B L Sb W Dg Ch Y G B G G Y Y L R G G W R W L L Ch Sb W Y R W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G G Y G Y G ...

Page 346: ...destand switch 19 Crankshaft position sensor 23 Lean angle sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right ignition coil 32 Spark plug 68 Engine stop switch 77 Ignition fuse 81 ECU fuse ...

Page 347: ...plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open 1 4 5 10 11 9 7 2 6 3 8 1 Battery 2 Main fuse ...

Page 348: ...r to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 7 82 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7...

Page 349: ...r to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE DI ODES on page 7 81 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 84 Replace the lean angle sensor 14 Check the entire ...

Page 350: ...IGNITION SYSTEM 7 6 ...

Page 351: ...L W G Br L R G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G B L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R B G R L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy Gy W BLACK R L B L Gy G Gy W B B W L R L Gy W Gy G B L Sb W Dg Ch Y G B G G Y Y L R G G W R W L L Ch Sb W Y R W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G G...

Page 352: ...ttery 8 Starter relay 9 Starter motor 10 Diode 1 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Diode 2 16 Sidestand switch 27 ECU electronic control unit 54 Clutch switch 68 Engine stop switch 69 Start switch 77 Ignition fuse 81 ECU fuse ...

Page 353: ...ulled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has bee...

Page 354: ...LED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Diode 2 7 Relay unit starting circuit cut off relay 8 Relay unit diode 9 Clutch switch 10 Sidestand switch 11 Neutral switch 12 Start switch 13 Starter relay 14 Starter motor 15 ECU fuse 16 ECU electronic control unit 17 Diode 1 ...

Page 355: ... Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 85 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 79 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 7 79 Re...

Page 356: ...witch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the sidestand switch 14 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the clutch switch 15 Check the start switch Refer to CHECKING THE SWITCHES on page 7 71 The start switch is fault...

Page 357: ...L L E Y BLACK L B B L Gy Gy B Gy B L B L L P Y B L L P W P W BLACK B L L P Y BLACK B L L W L B L W Y B L L B L W Y B L Br W BLACK Br B Br Br Br B B B B B Br W B L B G W R L B R L G W B B B L Y G L Br Br L R Br L Br L R B Br L R W R Y Br L R Y B R Y G L Br Y B G L R Y Br B R Gy W B G B B Y G W R Br P Y Br W R W L Y Gy P Y B Y Y G L R R L R B R B P W Br Br W L W W Y B L L B R W B R R W B R Br Br W B...

Page 358: ...CHARGING SYSTEM 7 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 6 Battery ...

Page 359: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 85 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 85 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUI...

Page 360: ...CHARGING SYSTEM 7 16 ...

Page 361: ... G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G B L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R B G R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy Gy W BLACK R L B L Gy G Gy W B B W L R L Gy W Gy G B L Sb W Dg Ch G B G G Y Y L R G G W R W L Ch Sb W Y R W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G G Y G Y G B G B ...

Page 362: ... 52 Headlight relay 55 Dimmer switch 59 Front right turn signal position light 60 Front left turn signal position light 64 Headlight high beam 65 Headlight low beam 70 Accessory light switch 71 Accessory light OPTION 72 Tail brake light 73 License plate light 78 Headlight fuse 79 Signaling system fuse 80 Taillight fuse 81 ECU fuse ...

Page 363: ...e fuses Main headlight signaling system taillight and ECU Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITC...

Page 364: ...LIGHTING SYSTEM 7 20 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 17 Properly connect or repair the lighting sys tem wiring The lighting system circuit is OK ...

Page 365: ...P L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G Gy Gy W BLACK R L B L Gy G Gy W B B W L R L G W Gy G B L Sb W Dg Ch Y G B G G Y Y L R G G W R W L L Ch Sb W Y R W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G Y Y G B ...

Page 366: ...arning light 45 Left turn signal indicator light 46 Right turn signal indicator light 48 Fuel sender fuel tank 49 Horn 1 50 Horn 2 51 Turn signal relay 56 Turn signal switch 57 Horn switch 59 Front right turn signal position light 60 Front left turn signal position light 61 Rear right turn signal light 62 Rear left turn signal light 67 Front brake light switch 72 Tail brake light 74 Rear brake lig...

Page 367: ...p ignition signaling system and ECU Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page...

Page 368: ...e the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the condition of each bulb and bulb socket Refer to CHECKING THE BULBS AND BULB SOCKETS on...

Page 369: ...elay unit diode Refer to CHECKING THE DI ODES on page 7 81 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the fuel sender fuel tank Refer to CHECKING THE FUEL SENDER FUEL TANK on page 7 87 Replace the fuel sender 2 Check the entire signaling system wiring Refer...

Page 370: ...k the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 7 88 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring Replace the meter...

Page 371: ... R G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G Br L R G R B R B R B R B R B R B C C Y B Gy W W R B G B R W R BLACK L W R G B R B L L B G B R B L W G GRAY W G DARK GRAY Gy G G Gy G B Gy Gy B W BLACK R L B L Gy G Gy W B B W L R L Gy W Gy G B L Sb W Dg Ch Y G B G G Y Y L R G G W R W L L Ch Sb W Y W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G G Y G Y ...

Page 372: ...nsor 25 Air temperature sensor 26 Engine temperature sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right ignition coil 32 Spark plug 33 ISC idle speed control unit 34 EXUP servo motor 35 Injector 1 36 Injector 2 37 O2 sensor 40 Multi function meter 41 Reset switch 42 Engine trouble warning lig...

Page 373: ...code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has...

Page 374: ...e system Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached hose Able Able 15 Throttle position sen sor open or short circuit Throttle position sensor open or short circuit detected Able Able 17 EXUP servo motor circuit open or short circuit EXUP servo motor circuit open or short circuit detected Able Able 18 EXUP servo motor lock EXUP servo motor is stuck Able Able ...

Page 375: ...n coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 37 ISC valve stuck fully open Engine speed is high when the en gine is idling Able Able 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Speed sensor No normal signals are received from the speed sensor Able Able Neutral switch Open ...

Page 376: ...een left idling The ECU automatically stops the en gine after 20 minutes if it is left idling Able Able Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unabl...

Page 377: ...ress the switch for 8 seconds or more NOTE All displays on the meter disappear except the clock and odometer trip meter fuel reserve trip meter clock displays dIAG appears on the odometer trip meter fuel reserve trip meter clock LCD 4 Simultaneously press the SELECT and RESET switches for 2 seconds or more to activate the diagnostic mode The diagnostic code number d01 appears on the clock LCD 5 Se...

Page 378: ...mproperly installed sensor 13 Cylinder 1 intake air pres sure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 1 intake air pressure sensor Malfunction in ECU 03 14 Cylinder 1 intake air pres sure sensor hose system malfunction clogged or de tached hose Cylinder 1 intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU ...

Page 379: ...hort circuit detected Open or short circuit in wire sub lead Open or short circuit in wire harness Defective engine temperature sensor Malfunction in ECU Improperly installed sensor 11 30 The vehicle has over turned Overturned Malfunction in ECU 08 33 Malfunction detected in the primary wire of the cylin der 1 left or right ignition coil Open or short circuit in wire harness Malfunction in cylinde...

Page 380: ... detected in the neutral switch Open circuit in wire harness Defective speed sensor Malfunction in vehicle speed sensor detect ed Defective neutral switch Malfunction in the engine side of the neutral switch Malfunction in ECU 07 21 43 The ECU is unable to moni tor the battery voltage an open or short circuit in the line to the ECU Open or short circuit in wire harness Malfunction in ECU 09 44 Err...

Page 381: ...nder 1 intake air pres sure Displays the cylinder 1 in take air pressure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK 04 Pressure difference atmospheric pressure and cylinder 2 intake air pres sure Displays the cylinder 2 in take air pressure Set the engine stop switch to and then push the start switch If the dis play value change...

Page 382: ...or Displays the operating angle Engine trouble warning light comes on twice once when the EXUP valve is closing and once when it is opening 60 EEPROM fault code dis play No history 00 History exists 01 or 02 Cylinder fault code If both cylinders are defec tive the display alternates every two seconds 61 Malfunction history code display No history 00 History exists Fault codes 12 70 If more than on...

Page 383: ... times Connect an ignition checker 33 Cylinder 2 left or right ig nition coil Actuates the cylinder 2 left or right ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Check the oper...

Page 384: ...nction table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 7 33 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and head light Check the operating sound of the headlight relay five times 54 ISC valve Actuates and full...

Page 385: ... Crankshaft position sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gra...

Page 386: ...ler 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 Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler black blue black blue pink white pink white blue blu...

Page 387: ...ting the en gine and oper ating it at idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Cylinder 1 intake air pressure sen sor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there ...

Page 388: ... pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler blue blue yellow yellow black black 4 Throttle position sensor lead wire open circuit output voltage check...

Page 389: ... Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 7 90 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking conditio...

Page 390: ...place if defective Refer to CHECKING THE SWITCHES on page 7 71 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of air temperature sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Ai...

Page 391: ...sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler gray white gray white red blue red blue gray green ...

Page 392: ...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 Turning the main switch to ON 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler black blue black blue pink yello...

Page 393: ...ting the en gine and oper ating it at idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Cylinder 2 intake air pressure sen sor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there ...

Page 394: ...ler brown brown black black 4 Defective engine temperature sensor Execute the diagnostic mode Code No 11 Replace if defective Refer to CHECKING THE EN GINE TEMPERATURE SEN SOR on page 7 87 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Rai...

Page 395: ... pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red b...

Page 396: ... any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 2 left or right ignition coil connector and ECU coupler main wire...

Page 397: ... pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red b...

Page 398: ... any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 2 left or right ignition coil connector and ECU coupler main wire...

Page 399: ...AY on page 3 8 3 ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is de tected with the ISC valve stuck fully open even though signals for the valve to close are continuously being trans mitted by the ECU Check that the ISC unit hose is not disconnected Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does...

Page 400: ...r 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 Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean angle ...

Page 401: ...ndition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black b...

Page 402: ...nd relay unit coupler fuel pump relay sky blue sky blue Between relay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 107 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITC...

Page 403: ...red blue red blue Between relay unit coupler fuel pump relay and battery termi nal red red Between relay unit coupler fuel pump relay and diode 2 cou pler red white red white Between diode 2 coupler and engine stop switch coupler black red black red 3 Malfunction or open circuit in relay unit fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction wit...

Page 404: ... 7 76 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 7 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main fuse red red Between main fuse and main switch red red Between main switch and igni tion fuse brown blue brown blue Between ignition fuse and ECU red white red white Fault code ...

Page 405: ...lue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the coupl...

Page 406: ...lue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the coupler...

Page 407: ...r L Gy R Gy R Gy R Gy R R G P L W G B L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W G DARK GRAY Gy G G Gy G B Gy Gy B W BLACK R L B L Gy G Gy W B B W L R L Gy W Gy G B L Sb W Dg Ch Y G B G G Y Y L R G G W R W L L Ch Sb W Y R W Dg L Sb Y Ch R W Dg BLACK G W B Y L G R G BLACK BLACK BLACK G W B Y L G R G G Y G Y G ...

Page 408: ...STEM 7 64 3 Main switch 4 Main fuse 6 Battery 7 Fuel injection system fuse 11 Relay unit 13 Fuel pump relay 15 Diode 2 17 Fuel pump 27 ECU electronic control unit 68 Engine stop switch 77 Ignition fuse 81 ECU fuse ...

Page 409: ... CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 71 The engine stop switch is faulty Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING...

Page 410: ...FUEL PUMP SYSTEM 7 66 NG OK 8 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 7 63 Properly connect or repair the fuel pump system wiring Replace the ECU ...

Page 411: ...ELECTRICAL COMPONENTS 7 67 EAS27970 ELECTRICAL COMPONENTS 11 3 6 7 8 10 4 9 12 13 5 2 1 14 ...

Page 412: ...t ignition coil 3 Fuel sender 4 Engine temperature sensor 5 Cylinder 1 left ignition coil 6 Cylinder 1 right ignition coil 7 ECU electronic control unit 8 EXUP servo motor 9 Speed sensor 10 Rectifier regulator 11 Neutral switch 12 Horn 2 13 Horn 1 14 ISC idle speed control unit ...

Page 413: ...ELECTRICAL COMPONENTS 7 69 16 18 2 11 13 9 8 10 12 14 15 17 1 3 4 5 6 7 ...

Page 414: ...4 Throttle position sensor 5 Cylinder 1 intake air pressure sensor 6 Fuse box 7 Starter relay 8 Fuel injection system fuse 9 Battery 10 Diode 2 11 Turn signal relay 12 Headlight relay 13 Relay unit 14 Diode 1 15 Main fuse 16 Lean angle cut off switch 17 Crankshaft position sensor 18 Rear brake light switch ...

Page 415: ...13 10 6 12 9 Y G L G B P Br Y R W B R L W W B R Br R Br L Y L B ON OFF G Y G B PUSH Ch Br W Dg B Y R L R GRAY Dg Ch GRAY B B G YG B BLUE Y G G L GRAY B P Y R Br W L Y B Y B B BLACK B B BLACK 8 7 BLUE B B R W B R G L L B BLACK W B L W 2 3 5 4 GRAY L Y L B 1 L B G L B B ...

Page 416: ...ch 2 Engine stop switch 3 Start switch 4 Accessory light switch 5 Front brake light switch 6 Neutral switch 7 Sidestand switch 8 Rear brake light switch 9 Clutch switch 10 Horn switch 11 Dimmer switch 12 Select switch 13 Turn signal switch ...

Page 417: ...er to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals a...

Page 418: ...ition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW1D71009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC1D71006 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 t...

Page 419: ... page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check...

Page 420: ...NTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC1D71020 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent f...

Page 421: ...ve it from the vehicle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make ...

Page 422: ...e charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant ...

Page 423: ...tinuity with the pocket tester If the continuity reading is incorrect re place the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminals as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay 12 8 V or more Charging is complete 12 7 V or less Recharging is required ...

Page 424: ...et tester DC 20 V to the turn signal relay terminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input voltage DC 12 V 3 1 2 4 R Y G L Br Y B ...

Page 425: ... Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky b...

Page 426: ... c Check the diode 2 for continuity d Check the diode 2 for no continuity ET1D71012 CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 7 4 NOTE If the ignition spark gap is within specification the ignition system circuit is operating normally Pocket tester 90890 03112 Ana...

Page 427: ...g cap as shown c Measure the spark plug cap resistance EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni tion coils 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check S...

Page 428: ... 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Secondary coil resistance 8 64 12 96 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe black red 1 Positive tester probe spark plug...

Page 429: ...rks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the rectifier regulator 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING ...

Page 430: ...rom the horn terminals b Connect the pocket tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the horn sound is obtained Charging voltage 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red 1 Nega...

Page 431: ...ensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the engine temperature sensor re sistance 3 Install Engine temperature sensor ET1D71014 CHECKING THE FUEL SENDER FUEL TANK 1 Remove Fuel sender from the fuel tank 2 Check Fuel sender resistance Out of specification Replace a Connect the pocket tes...

Page 432: ...el 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 three seconds in a repeated cycle mal function detected in fuel sender or thermistor Replace the fuel pump assembly EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sens...

Page 433: ...ine is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may ...

Page 434: ...ake air pressure sensors 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown b Turn the main switch to ON c Measure the intake air pressure sensor out put voltage ET1D71016 CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor Positive battery lead red blue 2 Negative ba...

Page 435: ...cket tester Ω 100 to the air temperature sensor terminals as shown b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the air temperature sensor resis tance Air temperature sensor re...

Page 436: ...ENGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 4 ...

Page 437: ...eriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged ele...

Page 438: ...ign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gea...

Page 439: ...ect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handleba...

Page 440: ...light LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal relay Faulty mai...

Page 441: ...OFF D D C C D D C D D E E E B B B B B B L N R PUSH A A BLACK A A A 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 32 32 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 81 80 A WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS2 E WIRE HARNESS SUB...

Page 442: ...rn 2 51 Turn signal relay 52 Headlight relay 53 Left handlebar switch 54 Clutch switch 55 Dimmer switch 56 Turn signal switch 57 Horn switch 58 Select switch 59 Front right turn signal position light 60 Front left turn signal position light 61 Rear right turn signal light 62 Rear left turn signal light 63 Headlight assembly 64 Headlight high beam 65 Headlight low beam 66 Right handlebar switch 67 ...

Page 443: ......

Page 444: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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