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Yamaha XVS13AW(C), Service Manual


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TRANSMISSION

5-86

3. Check:

• Transmission gears

Blue discoloration/pitting/wear 

→

 Replace 

the defective gear(s).

• Transmission gear dogs

Cracks/damage/rounded edges 

→

 Replace 

the defective gear(s).

4. Check:

• Transmission gear engagement

(each pinion gear to its respective wheel 
gear)
Incorrect 

→

 Reassemble the transmission 

axle assemblies.

5. Check:

• Transmission gear movement

Rough movement 

→

 Replace the defective 

part(s).

EAS3D81032

ASSEMBLING THE MAIN AXLE AND DRIVE 
AXLE

1. Install:

• Toothed washer

• Circlip “1” 

NOTE:

Install the circlip so that both ends “a” rest on the 
sides of a spline “b” 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 drive axle, align the projection 
“c” on the retainer with an axle spline “b”, and 
then install the toothed lock washer “2”.

• Be sure to align the projection on the toothed 

lock washer that is between the alignment 
marks “e” with the alignment mark “d” on the 
retainer.

EAS26320

INSTALLING THE SHIFT FORKS AND SHIFT 
DRUM ASSEMBLY

1. Install:

• Shift forks 1 “1”
• Shift fork 2 “2”
• Shift drum assembly “3”
• Long shift fork guide bar “4”
• Short shift fork guide bar “5”

NOTE:

The embossed marks “3D8” on the shift forks 
should face towards the left side of the engine.

New

a

b

1

New

d

b

2

1

e

e

1

2

c

b

a

Summary of Contents for XVS13AW(C)

Page 1: ...anuals 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...

Page 2: ...SERVICE MANUAL XVS13AW C XVS13CTW C LIT 11616 20 42 3D8 28197 10...

Page 3: ...006 by Yamaha Motor Corporation U S A First edition August 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly p...

Page 4: ...ded 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 it...

Page 5: ...b 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...

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 oi...

Page 7: ......

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

Page 9: ......

Page 10: ...OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS P...

Page 11: ...0140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This info...

Page 12: ...gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injectio...

Page 13: ...ntrolled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor coolant temperature sensor lean angle sensor s...

Page 14: ...e will sweep once across the speed range and then return to zero in order to test the electrical circuit Odometer tripmeter and fuel reserve trip meter modes Push the side of the SELECT switch to swit...

Page 15: ...release it to start the clock Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the engine trouble warn...

Page 16: ...orrect 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 f...

Page 17: ...ase 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 reassemb...

Page 18: ...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 C...

Page 19: ...below to avoid any mistakes NOTE For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket...

Page 20: ...3 Spanner wrench YU 33975 3 26 4 61 Damper rod holder 90890 01460 4 54 4 56 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 54 4 56 Fork seal driver 90890 01442 Adjustable fork seal driv...

Page 21: ...243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 33 Valve guide remover 6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 29 Valve guide installer 6 90890 04065 Valve guide installer 6...

Page 22: ...890 01701 Primary clutch holder YS 01880 A 5 43 5 44 5 51 5 54 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 43 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 45 5 71 6 10 Universal...

Page 23: ...e tester adapter YU 33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 10 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 10 Pressure...

Page 24: ...LS 1 14 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 11 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 83 Tool name Tool No Illustration Refe...

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

Page 26: ...ORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 25 LUBRICATIO...

Page 27: ...ions Overall length 2490 mm 98 0 in Overall width 980 mm 38 6 in Overall height XVS13AW C 1115 mm 43 9 in XVS13CTW C 1520 mm 59 8 in Seat height 715 mm 28 1 in Wheelbase 1690 mm 66 5 in Ground clearan...

Page 28: ...3 7 L 0 98 US gal 0 81 Imp gal Engine oil Lubrication system Wet sump Type YAMALUBE 4 20W40 or SAE20W40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity...

Page 29: ...th 197 0 mm 7 76 in Height 320 0 mm 12 60 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 70 45 17 26 1 017 Impeller shaft tilt limit 0 15 mm 0 006...

Page 30: ...alve dimensions Valve head diameter A intake 35 90 36 10 mm 1 4134 1 4213 in Valve head diameter A exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve seat width C intake 1 00 1 20 mm 0 0394 0 0472 in Valve...

Page 31: ...in Installed length exhaust 35 00 mm 1 38 in Spring rate K1 intake 24 75 N mm 141 32 lb in 2 52 kgf mm Spring rate K2 intake 34 93 N mm 199 45 lb in 3 56 kgf mm Spring rate K1 exhaust 24 75 N mm 141...

Page 32: ...0 15 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 030 0 080 mm 0 0012 0 0032 in Limit 0 130 mm 0 0051 in 2nd ring Ring type Taper Dimensions B T 1...

Page 33: ...2 80 mm 0 1102 in Plate quantity 2 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 1110 in Plate quantity 7 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plat...

Page 34: ...el injector Model quantity INP 284 2 Manufacturer NIKK Throttle body Type quantity ACW40 2 Manufacturer MIKUNI ID mark 3D81 00 USA CDN 3D82 10 California Throttle valve size 40 Throttle position senso...

Page 35: ...16M C 67H Manufacturer model DUNLOP D404F X Manufacturer model BRIDGESTONE EXEDRA G721 Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 170 70B 16M C 75H Manufacturer model DUNLOP K555 Man...

Page 36: ...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 Angular bearing Lock to lock angle l...

Page 37: ...1200 kPa 170 7 psi 12 0 kgf cm Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0...

Page 38: ...odel manufacturer F3D8 MORIC Standard output 14 0 V 32 9 A 5000 r min Standard output 14 0 V 460 W 5000 r min Stator coil resistance 0 112 0 168 Rectifier regulator Regulator type Semiconductor short...

Page 39: ...780 1021 gf Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768115 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 H...

Page 40: ...an motor relay Model manufacturer ACM33211 M05 MATSUSHITA Coil resistance 86 40 105 60 Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 15...

Page 41: ...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 speci...

Page 42: ...nder head blind plug M14 2 6 Nm 0 6 m kg 4 3 ft lb Spark plug M10 2 13 Nm 1 3 m kg 9 4 ft lb Tappet cover bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Timing chain tensioner housing bolt M6 2 10 Nm 1 0 m kg 7 2...

Page 43: ...clamp M6 6 6 Nm 0 6 m kg 4 3 ft lb See NOTE Rear cylinder exhaust pipe bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Exhaust pipe band bolt M8 2 12 Nm 1 2 m kg 8 7 ft lb Muffler band bolt M8 1 12 Nm 1 2 m kg 8 7...

Page 44: ...2 0 m kg 14 ft lb Speed sensor bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Starter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead nut M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator filler pipe bolt M6 2...

Page 45: ...NOTE Exhaust pipe cover screw clamp Do not retighten the exhaust pipe cover screw clamps always replace them with new ones if they are loosened Camshaft assembly tightening sequence Cylinder head tigh...

Page 46: ...coil bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear shock absorber assembly lower nut M10 1 48 Nm 4 8 m kg 35 ft lb Rear shock absorber assembly upper nut M10 1 48 Nm 4 8 m kg 35 ft lb Pivot shaft nu...

Page 47: ...1 10 Nm 1 0 m kg 7 2 ft lb Front fender bolt M8 4 23 Nm 2 3 m kg 17 ft lb Front brake hose guide bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Headlight body b...

Page 48: ...frame bolt M8 2 16 Nm 1 6 m kg 11 ft lb Passenger seat guide rear fend er and frame bolt M8 2 16 Nm 1 6 m kg 11 ft lb Passenger seat bolt M8 2 16 Nm 1 6 m kg 11 ft lb License plate bracket and rear f...

Page 49: ...2 7 Nm 0 7 m kg 5 1 ft lb Locknut rear brake master cylin der M8 1 16 Nm 1 6 m kg 11 ft lb Brake fluid reservoir bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator cover bolt M6 2 7 Nm 0 7 m kg 5...

Page 50: ...ors inner and outer and oil water pump housing Cylinder head bolts Starter clutch idle gear shaft Starter clutch idle gear Starter clutch gear inner and outer surfaces Torque limiter Primary driven ge...

Page 51: ...l to metal moving parts Throttle grip tube guide inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Brake master cylinder push rod contact surface Clutch leve...

Page 52: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 16 13 14 15 12 10 9 8 7 5 6 4 3 2 1 11 13...

Page 54: ...assembly 5 Drive axle 6 Oil filter cartridge 7 Main axle 8 Main gallery 9 Crankcase 10 Front cylinder piston oil nozzle 11 Rear cylinder piston oil nozzle 12 Rear cylinder timing chain tensioner 13 V...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS A A 1 2 2 3 A A...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil delivery pipe 3 3 Relief valve assembly...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 1 2 3...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Camshaft 2 Oil nozzle 3 Crankshaft...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil delivery pipe 1 2 Timing chain tensioner...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 2 3 4 5 6...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Drive axle 2 Oil delivery pipe 2 3 Main axle 4 Oil delivery pipe 3 5 Oil water pump assembly 6 Oil strainer...

Page 63: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20420 COOLING SYSTEM DIAGRAMS A A A A 2 1 4 3 5 6...

Page 64: ...OOLING SYSTEM DIAGRAMS 2 38 1 Rear cylinder thermostat inlet pipe 1 2 Front cylinder thermostat inlet pipe 1 3 Coolant delivery cover 2 4 Coolant delivery cover 1 5 Drain cock 6 Oil water pump assembl...

Page 65: ...COOLING SYSTEM DIAGRAMS 2 39 A B B A 4 3 3 1 2 2 A A B B...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 40 1 Radiator outlet hose 2 Radiator outlet pipe 3 Coolant delivery pipe 4 Oil water pump assembly...

Page 67: ...COOLING SYSTEM DIAGRAMS 2 41 10 13 4 7 3 1 10 9 6 B C A 12 11 C B A 1 8 9 10 10 12 3 2 4 5 6 7...

Page 68: ...cylinder thermostat inlet hose 4 Front cylinder thermostat inlet hose 5 Coolant reservoir hose 6 Rear cylinder thermostat inlet pipe 2 7 Thermostat assembly 8 Thermostat cover inlet hose 9 Thermostat...

Page 69: ...CABLE ROUTING 2 43 EAS20430 CABLE ROUTING LOWER D D A A B B E C E C A B B A D D A E B D F G H C 1 2 2 3 3 6 4 5 5 5 6 6 6 7 7 7 6 5 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 70: ...tch A Pass the clutch cable and left handlebar switch lead through the guide making sure to route the lead to the outside of the cable B Pass the throttle cables and right handlebar switch lead throug...

Page 71: ...CABLE ROUTING 2 45 A F F D D G G E E B C A F F G G E E D D B C A B C D E F G I 1 1 1 2 2 2 2 2 3 3 3 4 5 6 7 9 8 9 8 12 11 10 H...

Page 72: ...nt of the meter assembly couplers and front turn signal light couplers and then wrap the protective covering around the lead and couplers C Fasten the wire harness front turn signal light leads meter...

Page 73: ...2 47 C C E E F F H H B D G I D I A G B C C E F F H H E 4 2 4 4 4 2 2 2 11 12 A B C D E F G H J I K 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A 20 20 23 24 L L M N O P Q R S U T V W X Y 1 2 4...

Page 74: ...se I Fasten the rear brake light switch lead and horn lead to the frame with the tie making sure to face the end of the tie inward J Pass a plastic locking tie through the space between the frame and...

Page 75: ...CABLE ROUTING 2 49 C D D C C A A F E B A C B D E F F G 1 2 3 4 4 4 5 6 6 6 6 7 8 F A A D D C B E...

Page 76: ...ose with the bands B Install the rear brake hose onto the rear brake caliper making sure that the brake pipe touches the projection on the caliper C Face the ends of the hose clamp inward D Face the e...

Page 77: ...NG 2 51 A A B B C C D D E E G G F F E E D D A A B C C B G G F F 1 26 26 21 22 27 27 A 1 2 3 S S T 2 2 13 22 22 22 23 23 24 24 25 D E F 4 5 6 7 8 9 10 11 12 13 15 14 16 17 B C G H I J K L M N O P Q R U...

Page 78: ...excess end of the tie J The starter motor lead neutral switch lead and sidestand switch lead may be routed in any order in the area shown in the illustration K Fasten the starter motor lead at the pos...

Page 79: ...CABLE ROUTING 2 53 F F E E C C D D A B B C A 19 17 20 F F C E E C D D A B G H D E F I I J K L N M O P Q R S T U V 1 2 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 11 12 12 13 14 15 16 18...

Page 80: ...ward and then cut off the excess end of the tie K Insert the projection on the wire harness holder completely into the hole in the sub fuel tank bracket L Fasten the speed sensor lead crankshaft posit...

Page 81: ...UTING 2 55 B B C A D E E C D A B B A A 1 1 2 2 3 4 5 5 6 6 7 8 9 9 10 11 14 13 12 13 15 14 16 16 11 17 17 18 18 19 21 20 22 23 24 25 26 27 29 29 29 28 34 35 30 31 32 33 B C D E F G H I J K L M N O P Q...

Page 82: ...over any cable lead pipe or hose that it crosses in the area shown in the illustration F To fuel sender G Insert the projections on the wire harness holders completely into the holes in the frame H Ro...

Page 83: ...CABLE ROUTING 2 57 3D8 3D8 A B B A A B C D E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 84: ...e breather hose 16 ISC idle speed control unit 17 Canister purge hose California only A Install the front cylinder intake air pressure sensor hose with its yellow paint mark facing outward B Install t...

Page 85: ...CABLE ROUTING 2 59...

Page 86: ...urge hose California only and face the ends of the clamp forward D Route the canister purge hose California only to the outside of the front cylinder resonator hose and then install it onto the thrott...

Page 87: ...CABLE ROUTING 2 61 J J F F C A B E E F F C B A 1 2 1 3 4 5 6 7 7 9 9 8 8 1 1 1 3 10 10 11 14 14 15 17 16 12 13 A K B C D 4 9 E F G H D D 9 7 I 18 E D D E 19 20 20 16 15 21 19 22 L...

Page 88: ...k overflow hose identified by the paint mark over the fuel tank breather hose fuel tank to hose joint B Do not face the ends of the hose clamps inward C Install the air vent hose to the fuel tank with...

Page 89: ...CABLE ROUTING 2 63...

Page 90: ...3 16 CHECKING THE CANISTER California only 3 16 CHECKING THE COOLANT LEVEL 3 16 CHECKING THE COOLING SYSTEM 3 17 CHANGING THE COOLANT 3 17 CHASSIS 3 20 ADJUSTING THE FRONT BRAKE LEVER FREE PLAY 3 20 A...

Page 91: ...ELECTRICAL SYSTEM 3 31 CHECKING AND CHARGING THE BATTERY 3 31 CHECKING THE FUSES 3 31 REPLACING THE HEADLIGHT BULB 3 31 ADJUSTING THE HEADLIGHT BEAM 3 32...

Page 92: ......

Page 93: ...cks 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 wh...

Page 94: ...oap 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 assemb...

Page 95: ...ng in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reser...

Page 96: ...cylinder right cover Refer to ENGINE REMOVAL on page 5 1 2 Remove Throttle body Intake manifold assembly Refer to THROTTLE BODIES on page 7 7 3 Drain Coolant Refer to CHANGING THE COOLANT on page 3 17...

Page 97: ...degrees b When the rear cylinder piston is at TDC on the compression stroke align the TDC mark c on the generator rotor with the slot d in the generator cover NOTE When the piston is at TDC on the com...

Page 98: ...or to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level surface NO...

Page 99: ...the lower pressure is out of specification adjust it to specification first and then syn chronize the throttle bodies NOTE After each step rev the engine two or three times each time for less than a...

Page 100: ...to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Adjust Throttle cable free play Throttle body side a Loosen the locknut 1 on the accelerator ca ble b Turn the adjusting nut...

Page 101: ...rmal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specifica...

Page 102: ...yl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 2 Start...

Page 103: ...linder covers Front cylinder covers Refer to ENGINE REMOVAL on page 5 1 EAS20750 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make su...

Page 104: ...l completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O r...

Page 105: ...e oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 73 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil ch...

Page 106: ...ELEMENT 1 Remove Air filter case cover 1 2 Remove Air filter element 1 3 Check Air filter element Damage Replace NOTE The air filter needs more frequent service if you are riding in unusually wet or d...

Page 107: ...r vent and breather hoses 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Fuel hose 1 Air vent hose 2 Fuel cock hose 3 Fuel tank breather hose...

Page 108: ...Canister 1 Canister purge hose 2 Canister charge hose 3 Canister breather hose 4 Cracks damage Replace EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicl...

Page 109: ...up for several min utes and then turn it off 5 Check Coolant level NOTE Before checking the coolant level wait a few minutes until the coolant has settled EAS21120 CHECKING THE COOLING SYSTEM 1 Remov...

Page 110: ...lt radiator 1 along with the copper washer 4 Disconnect Radiator outlet hose 2 5 Drain Coolant from the engine and radiator 6 Remove Rear brake hose plastic holder 1 Rear brake hose guide bolts 2 Rear...

Page 111: ...water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 14 Install Radiator cap 15 Fill Coolant reservoir with...

Page 112: ...l adjusting bolt position Check that the end a of the brake pedal ad justing bolt is visible through the hole b Incorrect Adjust 2 Adjust Brake pedal adjusting bolt position a Loosen the locknut 1 b A...

Page 113: ...nder reservoir and brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and pla...

Page 114: ...fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 34 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The...

Page 115: ...system a Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid...

Page 116: ...the tight est point on the belt CAUTION ECA14950 A drive belt that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an...

Page 117: ...s 3 in direction a or b until the specified drive belt slack is ob tained NOTE Using the alignment marks on each side of the swingarm make sure that both belt pullers are in the same position for prop...

Page 118: ...t to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both di...

Page 119: ...ING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Remove Rear cylind...

Page 120: ...d vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place...

Page 121: ...n this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any...

Page 122: ...s and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate th...

Page 123: ...t bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 7 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUT...

Page 124: ...with a screw driver in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 with a screw driver in direction a or b Direction a Headlight beam is raised Direction b Head...

Page 125: ...ELECTRICAL SYSTEM 3 33...

Page 126: ...REPLACING THE FRONT BRAKE PADS 4 28 REMOVING THE FRONT BRAKE CALIPERS 4 29 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 29 CHECKING THE FRONT BRAKE CALIPERS 4 29 ASSEMBLING THE FRONT BRAKE CALIPERS 4 30 I...

Page 127: ...THE STEERING HEAD 4 61 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 65 DISPOSING OF A REAR SHOCK ABSORBER 4 65 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 CHECKING THE REAR...

Page 128: ......

Page 129: ...ove Q ty Remarks Turn signal light bracket cover Refer to GENERAL CHASSIS on page 4 1 1 Windshield 1 2 Windshield bracket left and right 2 For installation reverse the removal proce dure 1 2 2 T R 23...

Page 130: ...ft cloth and then treat with Yamaha Mink Oil or another high quality leather protectant for increased water resistance 2 Backrest 1 3 Passenger footrest left and right 2 4 Sidebag bracket plate 2 5 Si...

Page 131: ...ssenger seat 1 3 Sub fuel tank cover 1 4 Relay cover 1 5 Seat lock cable 1 Disconnect 6 Seat lock bracket 1 7 Left side cover 1 For installation reverse the removal proce dure 7 4 2 1 3 6 5 R 7 Nm 0 7...

Page 132: ...ight lens unit 1 3 Headlight coupler 1 Disconnect 4 Turn signal light coupler 2 Disconnect 5 Meter assembly coupler 3 Disconnect 6 Main switch coupler 2 Disconnect 7 Plastic band bracket 1 8 Headlight...

Page 133: ...band 1 2 Battery cover 1 3 Tool kit 1 4 Tool kit tray 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 ECU coupler 2 Disconnect 10 ECU engine...

Page 134: ...AL CHASSIS 4 6 15 Battery box 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 3 4 10 9 9 5 6 7 8 15 14 11 12...

Page 135: ...Q ty Remarks 1 Air filter case cover 1 2 Air filter element 1 3 Air filter case bracket 1 4 Crankcase breather hose 1 Disconnect 5 Air filter case 1 For installation reverse the removal proce dure T...

Page 136: ...Disconnect 3 Starter relay coupler 1 Disconnect 4 Starter relay 1 5 Crankshaft position sensor coupler 1 Disconnect 6 Tail brake light wire harness coupler 1 Disconnect 7 Stator coil coupler 1 Disconn...

Page 137: ...s Refer to FRONT BRAKE on page 4 22 1 Front brake caliper 2 2 Front wheel axle pinch bolt 1 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Front brake disc 2 For installation reverse the rem...

Page 138: ...FRONT WHEEL 4 10 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 139: ...wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gene...

Page 140: ...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 adjuste...

Page 141: ...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 stat...

Page 142: ...81011 Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly 6 Install Front brake calipers WARNING EWA3D81008 Make sure the brake...

Page 143: ...tray Refer to GENERAL CHASSIS on page 4 1 1 Tail brake light wire harness coupler 1 Disconnect 2 Rear fender bracket 2 3 Passenger seat bracket 1 4 Passenger seat guide 1 5 Rear fender assembly 1 6 M...

Page 144: ...spring 2 4 Drive belt adjusting locknut 2 Loosen 5 Drive belt adjusting bolt 2 Loosen 6 Rear wheel axle nut 1 7 Washer 1 8 Rear wheel axle 1 9 Right drive belt puller 1 10 Left drive belt puller 1 11...

Page 145: ...val proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks 3 1 2 LS LS T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb LS R 16 Nm 1 6 m kg 11...

Page 146: ...emarks 1 Rear brake disc 1 2 Rear wheel pulley 1 3 Oil seal 1 4 Circlip 1 5 Rear wheel drive hub 1 6 Circlip 1 7 Bearing 1 8 Collar 1 9 Bearing 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 For i...

Page 147: ...19 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Oil seal 1 4 Circlip 1 5 Bearing 1 6 Spacer 1 For assembly reverse the disassembly pro cedure 5 3 New Ne...

Page 148: ...CHECKING THE FRONT WHEEL on page 4 11 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 28 and CHECKING THE WHEELS on page 3 29 3 Measure Radial wheel runout Lateral wh...

Page 149: ...seal lips 2 Install Rear brake disc NOTE Apply locking agent LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 3 Check Rear brake disc R...

Page 150: ...f the front brake calipers 1 Reflector 1 2 Front brake caliper retaining bolt 2 3 Front brake caliper 1 4 Front brake pad 2 5 Brake pad shim 1 6 Front brake pad spring 1 7 Front brake pad support 2 Fo...

Page 151: ...4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Spring 1 7 Front brake light switch connector 2 Disconnect 8 Front brake hose union bolt 1 9 Copper washer 2 10 Front brake hose 1 11 Fr...

Page 152: ...ling 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...

Page 153: ...tor Refer to FRONT BRAKE on page 4 22 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake c...

Page 154: ...rs 1 Front brake caliper retaining bolt 2 2 Brake pad spring 1 3 Brake pad 2 4 Brake pad shim 1 5 Brake pad support 2 6 Brake caliper bracket 1 7 Brake caliper piston seal 4 8 Brake caliper piston 2 9...

Page 155: ...ure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake d...

Page 156: ...stic 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 Tigh...

Page 157: ...f the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA3...

Page 158: ...per 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on pa...

Page 159: ...page 3 22 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bo...

Page 160: ...he specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake per...

Page 161: ...FRONT BRAKE 4 33 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 LOWER a...

Page 162: ...ds Order Job Parts to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure 1 2 4 4 3...

Page 163: ...3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Locknut rear brake master cylinder 1 Loosen 7 Brake pedal adjusting bolt 1 Loosen 8 Rear brake hose unio...

Page 164: ...e removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib R 23 Nm 2 3 m kg...

Page 165: ...nder 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...

Page 166: ...fer 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 retaining bolt 2 5 Rear brake caliper 1 For installati...

Page 167: ...ing 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 New T R 6...

Page 168: ...lling 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 27 NOTE Measure the def...

Page 169: ...RAKE SYSTEM on page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper...

Page 170: ...enever 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 Rea...

Page 171: ...evel mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer...

Page 172: ...rake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling b...

Page 173: ...2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever 1 15 Clutch switch 1 16 Meter assembly cover 1 LT...

Page 174: ...ving the handlebar Order Job Parts to remove Q ty Remarks LT LT LS LS LS T R 10 Nm 1 0 m kg 7 2 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 T R 28 Nm 2 8 m kg 20 ft Ib R 23 Nm 2 3 m...

Page 175: ...so that there is no danger of it falling over 2 Install Handlebar 1 Front handlebar holders 2 CAUTION ECA3D81006 First tighten the bolts on the lower side of the front handlebar holder and then on th...

Page 176: ...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 7 Install Right handlebar switch 1 NOTE Align the projection...

Page 177: ...fer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 Clutch lever free play 5 0 10 0 mm 0 20 0 39 in...

Page 178: ...e 4 9 Rear handlebar holder Refer to HANDLEBAR on page 4 45 1 Front reflector 2 2 Brake hose guide 2 3 Reflector bracket 2 4 Front fender 1 5 Main switch coupler 2 Disconnect 6 Upper bracket pinch bol...

Page 179: ...1 For installation reverse the removal proce dure Removing the front fork legs Order Job Parts to remove Q ty Remarks 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 23 Nm 2 3 m kg 17 ft Ib...

Page 180: ...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...

Page 181: ...e 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 30 Nm 3 0 m kg 22 ft Ib...

Page 182: ...n 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 dampe...

Page 183: ...e front fork leg do not allow any foreign ma terial to enter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make...

Page 184: ...e 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 instal...

Page 185: ...down to distribute the fork oil 12 Install Spring Spring seat Spacer Cap bolt along with the O ring NOTE Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bol...

Page 186: ...E Align the grooves a in the upper front fork cover spacer 1 and groove b in the upper front fork cover 2 with the lower front fork cover bolts 3 6 Tighten Steering stem nut Cap bolt Upper bracket pin...

Page 187: ...al light 2 5 Front brake hose holder 1 6 Front brake hose joint 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Upper bearing cover 1 13 Upper bearing...

Page 188: ...e the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks LT R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb R 23 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft...

Page 189: ...ove 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 beari...

Page 190: ...3 26 3 Install Front brake hose joint 1 Front brake hose holder 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 o...

Page 191: ...reservoir Refer to RADIATOR on page 6 1 Sub fuel tank Refer to FUEL TANK on page 7 1 Rear wheel Refer to REAR WHEEL on page 4 15 1 Connecting arm nut Washer Bolt 2 2 2 2 Connecting arm 2 3 Rear shock...

Page 192: ...earing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks LS New New T R 9 10 11 9 1 1 2 7 2 1 8 10 12 6 6 6 3 3 3 5 4 4...

Page 193: ...shock absorber at a point 15 20 mm 0 60 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSOR...

Page 194: ...the relay arm Oil seals 4 to the relay arm EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacer 2 Tighten Relay arm nut 3 Install Rear shock absorber assembly NOTE Raise the swingar...

Page 195: ...REAR SHOCK ABSORBER ASSEMBLY 4 67 5 Install Connecting arms NOTE When installing the connecting arms lift up the swingarm T R Rear shock absorber assembly lower nut 48 Nm 4 8 m kg 35 ft lb...

Page 196: ...nect 3 Rectifier regulator 1 4 Drive belt adjusting bolt 2 5 Drive belt adjusting locknut 2 6 Drive belt upper guard 1 7 Drive belt lower guard 1 8 Pivot shaft nut 1 9 Pivot shaft 1 10 Swingarm 1 11 S...

Page 197: ...the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks LS LS LS LS LT R 16 Nm 1 6 m kg 11 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 T R 85 Nm 8 5 m kg...

Page 198: ...he swingarm vertical movement is not smooth or if there is binding check the spac ers bearings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Che...

Page 199: ...first tight en the upper bolt then the lower bolt 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 2 Swingarm A Left side B Right side Installed depth a 0 1 0 mm 0 0 04...

Page 200: ...to REAR WHEEL on page 4 15 Swingarm Refer to SWINGARM on page 4 68 1 Drive pulley cover 1 2 Drive belt 1 3 Drive pulley nut 1 4 Drive pulley 1 For installation reverse the removal proce dure New LT T...

Page 201: ...0 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 wh...

Page 202: ...ulley cover plate bolt NOTE Tighten the drive pulley cover plate bolts tempo rarily and then tighten them in proper tightening sequence as shown 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE...

Page 203: ...BELT DRIVE 4 75...

Page 204: ...COVERS 5 23 CYLINDER HEADS 5 24 REMOVING THE CYLINDER HEADS 5 25 CHECKING THE CYLINDER HEADS 5 25 INSTALLING THE CYLINDER HEADS 5 25 VALVES AND VALVE SPRINGS 5 27 REMOVING THE VALVES 5 28 CHECKING THE...

Page 205: ...LLING THE SHIFT SHAFT 5 58 BALANCER GEARS 5 59 CHECKING THE RIGHT BALANCER GEARS 5 61 CHECKING THE LEFT BALANCER GEARS 5 61 INSTALLING THE RIGHT BALANCER GEARS 5 61 INSTALLING THE LEFT BALANCER GEARS...

Page 206: ...77 INSTALLING THE CONNECTING RODS 5 79 INSTALLING THE CRANKSHAFT ASSEMBLY 5 80 TRANSMISSION 5 81 CHECKING THE SHIFT FORKS 5 85 CHECKING THE SHIFT DRUM ASSEMBLY 5 85 CHECKING THE TRANSMISSION 5 85 ASSE...

Page 207: ...Muffler bracket 1 10 O2 sensor 1 11 Coolant reservoir cover 1 For installation reverse the removal proce dure 6 1 T R 4 Nm 0 4 m kg 2 9 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 44...

Page 208: ...HAUST PIPE COVER SCREW CLAMPS 1 Install Exhaust pipe cover screw clamps NOTE Do not retighten the exhaust pipe cover screw clamps always replace them with new ones if they are loosened T R Exhaust pip...

Page 209: ...1 5 Left footrest assembly 1 6 Rear brake light switch 1 7 Right footrest assembly 1 8 Front cylinder left cover 1 9 Front cylinder right cover 1 10 Rear cylinder left cover 1 11 Rear cylinder right...

Page 210: ...ob Parts to remove Q ty Remarks T R 64 Nm 6 4 m kg 46 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib R 24 Nm 2 4 m kg 17 ft Ib T R 56 Nm 5 6 m kg 40 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 8 Nm 0 8 m kg 5 8 f...

Page 211: ...bolts temporarily and then tighten the front bolt then the rear bolt to spec ification EAS3D81018 INSTALLING THE SHIFT ARM 1 Install Shift arm 1 NOTE Align the I mark a in the shift shaft with the pun...

Page 212: ...y Refer to THROTTLE BODIES on page 7 7 Starter motor Refer to ELECTRIC STARTER on page 5 62 1 Oil level switch coupler 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankcase breather hose 1 4 Stator c...

Page 213: ...ENGINE REMOVAL 5 7 11 Rubber cover 1 For assembly reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 1 9 10 2 3 4 5 7 6 8 11 9...

Page 214: ...11 Engine mounting bolt rear lower side 1 12 Engine bracket bolt rear upper side 2 13 Engine bracket rear upper side 1 14 Engine bracket bolt rear lower side 2 15 Engine bracket rear lower side 1 16...

Page 215: ...gine Order Job Parts to remove Q ty Remarks R 48 Nm 4 8 m kg 35 ft Ib R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib R 30 Nm 3 0 m kg 22 ft Ib R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft...

Page 216: ...side 17 Engine mounting nut front lower side 18 NOTE Apply locking agent LOCTITE to the threads of the engine mounting bolts front right upper side engine bracket bolts rear lower side engine bracket...

Page 217: ...de 13 Engine mounting nut front lower side 16 T R Engine mounting bolt front right upper side 48 Nm 4 8 m kg 35 ft lb LOCTITE Engine mounting bolt front left upper side 48 Nm 4 8 m kg 35 ft lb LOCTITE...

Page 218: ...45 mm 1 77 in 7 Rear cylinder head cover bolt 2 l 55 mm 2 17 in 8 Rear cylinder head cover bolt 2 l 30 mm 1 18 in 9 Rear cylinder head cover bracket 1 10 Front cylinder head cover 1 11 Rear cylinder h...

Page 219: ...g 1 8 Front cylinder timing chain tensioner housing gasket 1 9 Camshaft sprocket 2 10 Rear cylinder camshaft assembly 1 11 Front cylinder camshaft assembly 1 For installation reverse the removal proce...

Page 220: ...alve clearance adjusting screw 4 3 Intake rocker arm shaft 1 4 Exhaust rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Circlip 1 8 Front cylinder camshaft 1 9 Rear cylinder camshaft...

Page 221: ...mark c on the camshaft sprocket with the arrow mark d on the front cylinder camshaft carrier 2 Remove Front cylinder timing chain tensioner 1 NOTE Never remove a timing chain tensioner when the engine...

Page 222: ...ensioner Rear cylinder camshaft sprocket Rear cylinder camshaft assembly NOTE Never remove a timing chain tensioner when the engine is mounted Remove the parts using the same procedure as for the fron...

Page 223: ...lies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Rocker arm roller Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or c...

Page 224: ...hain tensioner clips Damage wear Replace the as a set 3 Assemble Timing chain tensioner NOTE Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain ten sioner ho...

Page 225: ...NSTALLING THE CAMSHAFTS AND ROCKER ARMS The following procedure applies to all of the rocker arms and camshafts 1 Lubricate Camshaft 2 Install Camshaft 1 Circlip 2 NOTE Position the camshaft as shown...

Page 226: ...troke align the TDC mark a on the generator rotor with the slot b in the generator cover c Install the timing chain 1 onto the front cylin der camshaft sprocket 2 then install the camshaft sprocket on...

Page 227: ...a on the front cylinder timing chain tensioner should face up Push the end of the front cylinder timing chain guide intake side 3 to release the timing chain tensioner rod 6 Install Rear cylinder cam...

Page 228: ...haft carrier The rear cylinder camshaft assembly does not have a punch mark Be sure to install the cam shaft assembly without a punch mark onto the rear cylinder When installing the rear cylinder cams...

Page 229: ...ts 2 l 30 mm 1 18 in Bolts 3 l 45 mm 1 77 in Bolts 4 l 55 mm 2 17 in 2 Install Front cylinder head cover Front cylinder head cover bracket 1 Bolts 2 l 30 mm 1 18 in Bolts 3 l 45 mm 1 77 in Bolts 4 l 5...

Page 230: ...Oil check bolt 2 2 Front cylinder head 1 3 Rear cylinder head 1 4 Cylinder head gasket 2 5 Dowel pin 4 For installation reverse the removal proce dure T R 15 Nm 1 5 m kg 11 ft Ib R 15 Nm 1 5 m kg 11...

Page 231: ...Spark plug bore threads Valve seats 2 Check Cylinder heads Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thi...

Page 232: ...e oil Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head nut 65 Nm 6 5 m kg 47 ft lb Cylinder head bolt 13 Nm 1 3 m kg...

Page 233: ...re applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 24 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...

Page 234: ...cotters NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve...

Page 235: ...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 Valve stem to valve guide clear ance intake 0 01...

Page 236: ...the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dyke...

Page 237: ...h 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...

Page 238: ...ve stem 1 Valve stem seal 2 with the recommended lubricant 3 Lubricate Valve stem end with the recommended lubricant 4 Install Lower spring seat 1 Installed compression spring force intake 171 197 N 3...

Page 239: ...e valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve...

Page 240: ...DER HEADS on page 5 24 1 Timing chain guide 2 2 Front cylinder 1 3 Rear cylinder 1 4 Front cylinder gasket 1 5 Rear cylinder gasket 1 6 Dowel pin 4 7 Circlip 4 8 Piston pin 2 9 Piston 2 10 Top ring 2...

Page 241: ...n 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 pisto...

Page 242: ...g side clearance Out of specification Replace 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 p...

Page 243: ...Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 10 mm 0 39 in Piston ring Top ring End ga...

Page 244: ...front side of the cylinder Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase Install the piston pin clips so tha...

Page 245: ...ND PISTONS 5 39 6 Install Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide through the timing chai...

Page 246: ...7 Drive pulley cover Refer to BELT DRIVE on page 4 72 Left footrest assembly Sidestand Refer to ENGINE REMOVAL on page 5 1 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Dis...

Page 247: ...n sensor 1 11 Stator coil 1 For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks R 10 Nm 1 0 m kg 7 2 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 N...

Page 248: ...Q ty Remarks 1 Generator rotor 1 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Torque limiter 1 6 Starter clutch idle gear shaft 1 7 Starter clutch idle gear 1 For installation revers...

Page 249: ...the starter clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch NOTE While holding the generator...

Page 250: ...E While holding the generator rotor 1 with the sheave holder 2 tighten the starter clutch bolts EAS24500 INSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt NOTE Clean the t...

Page 251: ...GENERATOR AND STARTER CLUTCH 5 45 3 Apply Sealant onto the crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 90890 85505 Three Bond No 1215...

Page 252: ...rain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Clutch cable holder 1 2 Clutch cable 1 Disconnect 3 Pull lever 1 4 Pull lever spring 1 5 Damper cover 1 6 Clutch cover damper 1 7 Clutch cover 1 8...

Page 253: ...Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure LS New E 4 5...

Page 254: ...8 Friction plate 2 7 Inside diameter 124 mm 4 88 in 9 Clutch boss nut 1 10 Conical spring washer 1 11 Wire circlip 1 12 Clutch plate 1 13 Friction plate 3 1 Inside diameter 135 mm 5 31 in 14 Clutch da...

Page 255: ...pump drive sprocket 1 23 Thrust washer 2 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New...

Page 256: ...Down tube Refer to ENGINE REMOVAL on page 5 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 40 1 Primary drive gear cover 1 2 Primary drive gear cover gasket 1 3 Dowel pin 3 4 Primar...

Page 257: ...drive gear nut 1 Lock washer 2 NOTE While holding the generator rotor 3 with the sheave holder 4 loosen the primary drive gear nut Do not allow the sheave holder to touch the projection on the genera...

Page 258: ...spring plate seat Damage Replace EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the c...

Page 259: ...inion gear as a set 2 Check Pull rod bearing Damage wear Replace EAS3D81028 CHECKING THE OIL WATER PUMP DRIVE SPROCKET AND OIL WATER PUMP DRIVE CHAIN 1 Check Oil water pump drive sprocket Cracks damag...

Page 260: ...clutch housing Lubricate the clutch housing bearing with en gine oil Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly After installing the clutch housing make s...

Page 261: ...the tab of each friction plate 2 1 with the mark a on the clutch hous ing and align the cutout in the tab of friction plate 1 2 with the punch mark b on the hous ing 7 Install Clutch spring plate Clu...

Page 262: ...CLUTCH 5 56 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 2 1 c b a...

Page 263: ...E on page 4 72 Shift arm Refer to ENGINE REMOVAL on page 5 1 Primary drive gear cover Refer to CLUTCH on page 5 46 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 S...

Page 264: ...ghly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 NOTE Lubricate the oil seal lips with lithium soap based grease Hook t...

Page 265: ...Order Job Parts to remove Q ty Remarks Primary drive gear Refer to CLUTCH on page 5 46 1 Straight key 1 2 Right balancer drive gear 1 3 Right balancer assembly 1 For installation reverse the removal...

Page 266: ...ve Q ty Remarks Generator rotor Starter clutch idle gear Refer to GENERATOR AND STARTER CLUTCH on page 5 40 1 Left balancer drive gear 1 2 Left balancer assembly 1 For installation reverse the removal...

Page 267: ...y 2 Install Right balancer drive gear 1 Straight key 2 NOTE Align the punch mark a in the right balancer driven gear with the punch mark b in the right balancer drive gear EAS3D81027 INSTALLING THE LE...

Page 268: ...RIC 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 R 10 Nm 1 0 m kg 7 2 f...

Page 269: ...er set 1 5 Oil seal 1 6 Bearing 1 7 Armature assembly 1 8 Washer set 1 9 Starter motor rear cover 1 10 Gasket 2 11 Brush set along with the brushes 1 12 Brush holder along with the brushes 1 13 Brush...

Page 270: ...s 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 s...

Page 271: ...THE STARTER MOTOR 1 Install Brush seat NOTE Align the tab a on the brush seat with the slot b in the starter motor yoke 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear c...

Page 272: ...uide 2 6 Timing chain 2 7 Coolant delivery pipe 1 8 Speed sensor 1 9 Spacer 1 10 Oil filter cartridge 1 11 Oil delivery pipe 2 1 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 k...

Page 273: ...b Parts to remove Q ty Remarks 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 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib...

Page 274: ...oint pipe 2 1 6 Oil baffle plate 2 1 7 Gasket 1 8 Right crankcase 1 For installation reverse the removal proce dure 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 T...

Page 275: ...page 5 73 Crankshaft Refer to CRANKSHAFT on page 5 76 Transmission Refer to TRANSMISSION on page 5 81 1 Bearing retainer 2 2 Oil seal 1 3 Bearing 7 4 Oil nozzle 2 For installation reverse the removal...

Page 276: ...ressed air EAS3D81029 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace Oil seals Damage wear Repl...

Page 277: ...onto the crankcase mating surfaces NOTE Do not allow any sealant to come into contact with the oil gallery 3 Install Left crankcase onto the right crankcase NOTE Tap lightly on the left crankcase with...

Page 278: ...CASE 5 72 5 Apply Engine 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 A 1 2 3 3 3...

Page 279: ...assembly 1 4 Dowel pin 2 5 Joint pipe 1 6 Oil pump housing 1 7 Bearing 1 8 Pin 2 9 Oil pump outer rotor 1 10 Oil pump inner rotor 1 11 Pin 1 12 Water pump housing 1 For installation reverse the remov...

Page 280: ...peration Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage wear Replac...

Page 281: ...nstalling the inner rotor align the pin in the impeller shaft with the grooves a in the in ner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 74 EAS25020 INSTALLING THE OIL...

Page 282: ...case Separate Refer to CRANKCASE on page 5 66 1 Crankshaft 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bearing 2 For installation reverse the removal proce du...

Page 283: ...lies 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 da...

Page 284: ...to REMOVING THE CONNECTING RODS on page 5 77 g Measure the compressed Plastigauge width e on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select re pl...

Page 285: ...commended lubricant 2 Lubricate Crankshaft pin Big end bearings Connecting rod inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the cran...

Page 286: ...en 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 ECA3D81012 Do not use a torque wrench...

Page 287: ...to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift drum assembly 1 4 Shift fork 1 2 5 Shift fork 2 1 6 Main...

Page 288: ...ts to remove Q ty Remarks 1 Circlip 1 2 2nd pinion gear 1 3 Circlip 1 4 3rd 4th pinion gear 1 5 Circlip 1 6 Toothed washer 1 7 5th pinion gear 1 8 Collar 1 9 Main axle 1st pinion gear 1 For assembly r...

Page 289: ...h wheel gear 1 5 Circlip 1 6 Toothed washer 1 7 4th wheel gear 1 8 Toothed spacer 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 3rd wheel gear 1 12 Toothed spacer 1 13 Toothed washer...

Page 290: ...r 1 19 Collar 1 20 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks New New New M M M M M M M 20 19 18 17 16 15...

Page 291: ...movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift dru...

Page 292: ...he sides of a spline b 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 drive axle align the p...

Page 293: ...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 tu...

Page 294: ...NG THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUM...

Page 295: ...OOLANT on page 3 17 1 Rear brake hose guide 1 2 Rear brake hose holder 1 3 Plastic holder 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir hose 1 6 Coolant reservoir cap 1 7 Coolant reservoir...

Page 296: ...iator fan 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks LS R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 297: ...d make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system wi...

Page 298: ...hose 1 2 Front cylinder thermostat inlet pipe 1 1 3 Rear cylinder thermostat inlet hose 1 4 Rear cylinder thermostat inlet pipe 1 1 5 Coolant temperature sensor coupler 1 Disconnect 6 Coolant tempera...

Page 299: ...nder thermostat inlet pipe 2 1 18 Thermostat housing 1 For installation reverse the removal proce dure Removing the thermostat Order Job Parts to remove Q ty Remarks R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm...

Page 300: ...or overcooling 2 Check Thermostat housing cover Thermostat housing Thermostat pipes Thermostat hoses Radiator inlet hose Radiator filler pipe Cracks damage wear Replace EAS26480 INSTALLING THE THERMO...

Page 301: ...ankcase Separate Refer to CRANKCASE on page 5 66 Oil pump rotors Refer to OIL PUMP on page 5 73 1 Water pump housing cover 1 2 Pin 2 3 O ring 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber dam...

Page 302: ...rse the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks 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 R 24 Nm 2 4 m kg 17 ft Ib L...

Page 303: ...pump housing cover Water pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the oil water pump...

Page 304: ...90 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890...

Page 305: ...WATER PUMP 6 11...

Page 306: ...ION 7 5 CHECKING THE FUEL PUMP BODY 7 5 CHECKING THE ROLLOVER VALVE 7 5 INSTALLING THE FUEL PUMP 7 6 INSTALLING THE FUEL TANK HOSES 7 6 THROTTLE BODIES 7 7 CHECKING THE INJECTORS 7 11 CHECKING THE THR...

Page 307: ...l 1 4 Fuel sender coupler 1 Disconnect 5 Fuel cock hose 1 NOTE Before removing the fuel cock hose turn the fuel cock to OFF 6 Air vent hose 1 7 Fuel tank overflow hose 1 8 Fuel tank breather hose fuel...

Page 308: ...verse the removal proce dure Removing the fuel tank Order Job Parts to remove Q ty Remarks 23 Nm 2 3 m kg 17 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib New R 7 Nm 0 7 m kg 5 1 ft Ib N...

Page 309: ...Battery box Refer to GENERAL CHASSIS on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Sub fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump gasket 1 6 Fuel pump 1 For installation...

Page 310: ...1 1 Canister purge hose 1 California only 2 Fuel tank breather hose rollover valve to canis ter 1 California only 3 Fuel tank breather hose 1 Except for California 4 Fuel tank breather hose hose joint...

Page 311: ...emoved 2 Remove Fuel pump CAUTION ECA3D81001 Do not drop the fuel pump or give it a strong shock EAS26650 CHECKING THE FUEL COCK 1 Check Fuel cock Cracks damage wear Replace 2 Check Fuel cock strainer...

Page 312: ...cted 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 pump un...

Page 313: ...position sensor coupler 1 Disconnect 2 Canister purge hose 1 California only Disconnect 3 Front cylinder intake air pressure sensor hose 1 4 Rear cylinder intake air pressure sensor hose 1 5 Throttle...

Page 314: ...le position sensor 1 For installation reverse the removal proce dure Removing the throttle body and ISC idle speed control unit Order Job Parts to remove Q ty Remarks 2 4 3 8 9 6 5 1 7 10 5 New New LS...

Page 315: ...1 2 Ignition coil bracket bolt 2 3 Front cylinder resonator hose 1 4 Rear cylinder resonator hose 1 5 Resonator hose joint 1 6 Fuel hose 1 Disconnect 7 Sub wire harness coupler 2 Disconnect 8 Intake...

Page 316: ...Q ty Remarks 1 Front cylinder injector coupler 1 Disconnect 2 Rear cylinder injector coupler 1 Disconnect 3 Sub wire harness 1 4 Injector 2 5 Fuel pipe 1 6 Intake manifold 1 For assembly reverse the d...

Page 317: ...ng the hoses c Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel pump 2 d Connect the pressure gauge 4 to the fuel pressure adapter 3 e Start the engine f Measure the fuel pressure...

Page 318: ...nstall the front cylinder intake manifold joint with its projection a facing up as shown in the illus tration b Install the rear cylinder intake manifold joint 2 to the intake manifold assembly NOTE M...

Page 319: ...THROTTLE BODIES 7 13...

Page 320: ...AM 8 13 TROUBLESHOOTING 8 15 LIGHTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TRO...

Page 321: ...ION SENSOR 8 84 CHECKING THE LEAN ANGLE SENSOR 8 84 CHECKING THE STARTER MOTOR OPERATION 8 85 CHECKING THE STATOR COIL 8 85 CHECKING THE RECTIFIER REGULATOR 8 85 CHECKING THE HORN 8 86 CHECKING THE OI...

Page 322: ......

Page 323: ...ACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE HARNESS...

Page 324: ...tery 12 Relay unit 16 Neutral switch 18 Sidestand switch 20 Crankshaft position sensor 24 Lean angle sensor 27 ECU engine control unit 28 Rear cylinder ignition coil 29 Front cylinder ignition coil 30...

Page 325: ...venting the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sid...

Page 326: ...ge 8 75 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Regap or replace the spark plug s 4 Check the ignition spark g...

Page 327: ...WITCHES on page 8 71 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING T...

Page 328: ...IGNITION SYSTEM 8 6...

Page 329: ...E Gy Y R B Y G G L B Y P G Y R R Y L Y B Y B G L B L B Y G L B L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L ON OFF RESET Br L Br Br Br R W R R Y B Y B B B Y L R L Br Y Y L Y L B Br Y B G...

Page 330: ...se 5 Main switch 6 Battery 8 Starter relay 9 Starter motor 10 Diode 1 12 Relay unit 13 Starting circuit cut off relay 15 Diode 2 16 Neutral switch 18 Sidestand switch 52 Clutch switch 65 Engine stop s...

Page 331: ...s pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither o...

Page 332: ...CLUTCH LEVER IS PULLED 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 swit...

Page 333: ...inals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 85 The starter motor is OK Perform the elec tric starting system trou...

Page 334: ...page 8 71 Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWIT...

Page 335: ...B Dg Ch Br W BLUE BLACK Gy Y R B Y G G L B Y P G Y R R Y L Y B Y B G L B L B Y G L B L B GRAY GRAY Ch L B Ch L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L ON OFF L N R Br L Br Br Br R W R...

Page 336: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 3 Main fuse 6 Battery...

Page 337: ...to CHECKING AND CHARGING THE BATTERY on page 8 75 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 85 Replace the cranksh...

Page 338: ...CHARGING SYSTEM 8 16...

Page 339: ...CK BLACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A W RE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE HA...

Page 340: ...r 41 High beam indicator light 43 Meter light 49 Headlight relay 51 Dimmer switch 57 Front right turn signal light 58 Front left turn signal light 59 Headlight 60 Accessory light OPTION 67 License pla...

Page 341: ...KETS on page 8 74 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight signaling system ignition and taillight Refer to CHECKING THE FUS ES on page 8 75 Replace the fuse s 3 Check the...

Page 342: ...LIGHTING SYSTEM 8 20 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting sys tem s wiring Replace the ECU or meter assembly...

Page 343: ...BLACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B B W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB W REHARNESS B W RE HARNESS SUB W REHARNESS C WIRE HARNE...

Page 344: ...ral indicator light 38 Multi function meter 40 Coolant temperature warning light 42 Turn signal indicator light 44 Oil level switch 45 Fuel sender 47 Horn 48 Turn signal relay 53 Turn signal switch 54...

Page 345: ...Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 75 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING TH...

Page 346: ...ront brake light switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the rea...

Page 347: ...he neutral switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE DI ODES on page 8 81 Replace the relay unit 3 Check the enti...

Page 348: ...ng Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 88 Replace the coolant temperature sensor 2 Check the entire signaling...

Page 349: ...LACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE HARNES...

Page 350: ...LING SYSTEM 8 28 3 Main fuse 5 Main switch 6 Battery 11 Radiator fan motor fuse 25 Coolant temperature sensor 27 ECU engine control unit 69 Radiator fan motor 71 Radiator fan motor relay 73 Ignition f...

Page 351: ...inals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOT...

Page 352: ...COOLING SYSTEM 8 30...

Page 353: ...BLACK BLACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B B W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A W RE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE...

Page 354: ...cylinder intake air pressure sensor 24 Lean angle sensor 25 Coolant temperature sensor 26 Air temperature sensor 27 ECU engine control unit 28 Rear cylinder ignition coil 29 Front cylinder ignition co...

Page 355: ...ometer tripme ter fuel reserve tripmeter clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel...

Page 356: ...le un able to start Able un able to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Front cylinder intake air pressure sensor o...

Page 357: ...peed 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 receiv...

Page 358: ...g sensors and actuators in the diagnostic mode Refer to Sensor operation table and Actuator op eration table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts...

Page 359: ...ic code number d01 appears on the clock LCD 5 Set the engine stop switch to 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET switches NOTE T...

Page 360: ...Defective throttle position sensor Malfunction in ECU Improperly installed throttle position sensor 01 19 A break or disconnection of the blue black lead of the ECU is detected Open circuit in wire ha...

Page 361: ...ion in ECU 54 41 Lean angle sensor open or short circuit detected Open or short circuit in wire harness Defective lean angle sensor Malfunction in ECU 08 42 No normal signals are re ceived from the sp...

Page 362: ...22 Check with throttle fully closed Fully opened position 87 107 Check with throttle fully open 03 Pressure difference atmospheric pressure and front cylinder intake air pressure Displays the front cy...

Page 363: ...form recharging 20 Sidestand switch Set on off the sidestand switch with the transmis sion in gear Sidestand retracted ON Sidestand extended OFF 21 Neutral switch Shift the transmission Neutral ON In...

Page 364: ...ark five times Connect an ignition checker 36 Front cylinder injector Actuates the front cylinder in jector five times at one sec ond intervals Illuminates the engine trou ble warning light Check the...

Page 365: ...51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and rotates the radiator fa...

Page 366: ...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 an...

Page 367: ...e 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 s...

Page 368: ...tarting the en gine and oper ating it at idle 2 Front cylinder intake air pressure sen sor malfunction at intermediate elec trical potential Check and repair the connec tion Replace it if there is a m...

Page 369: ...eck 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 ci...

Page 370: ...ve Refer to CHECKING THE SWITCHES on page 8 71 Fault code No 21 Symptom Coolant temperature sensor open or short circuit detect ed Diagnostic code No 06 Coolant temperature sensor Order Item component...

Page 371: ...emperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the...

Page 372: ...sor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se cur...

Page 373: ...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 circu...

Page 374: ...here is a malfunction repair it and connect the coupler se curely 4 Defective rear cylinder intake air pres sure sensor Execute the diagnostic mode Code No 04 Replace if defective Refer to CHECKING TH...

Page 375: ...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 harn...

Page 376: ...cking 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 harnes...

Page 377: ...ne 2 ISC valve is stuck fully open due to disconnected ISC unit coupler High engine idling speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuo...

Page 378: ...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...

Page 379: ...condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the speed sensor by operating the vehicle at 20 to 30 km h A 2 Open...

Page 380: ...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 neutr...

Page 381: ...blue Between relay unit coupler fuel pump relay and starter relay coupler red red Between relay unit coupler fuel pump relay and diode 2 cou pler blue white blue white Between diode 2 coupler and rig...

Page 382: ...nction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery...

Page 383: ...ue 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 Diagnos...

Page 384: ...ue 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 Diagnosti...

Page 385: ...ACK BLACK GRAY GRAY BLACK BLACK Br L B Ch L G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE HARNESS...

Page 386: ...FUEL PUMP SYSTEM 8 64 3 Main fuse 5 Main switch 6 Battery 7 Fuel injection system fuse 14 Fuel pump relay 15 Diode 2 17 Fuel pump 27 ECU engine control unit 65 Engine stop switch 73 Ignition fuse...

Page 387: ...D CHARGING THE BATTERY on page 8 75 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the main switch 4 Check the...

Page 388: ...FUEL PUMP SYSTEM 8 66 NG OK 8 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 63 Properly connect or repair the fuel pump system s wiring Replace the ECU...

Page 389: ...ELECTRICAL COMPONENTS 8 67 EAS27970 ELECTRICAL COMPONENTS 1 4 5 6 7 8 9 10 11 12 13 2 3...

Page 390: ...e air pressure sensor 3 Rear cylinder intake air pressure sensor 4 Rear cylinder ignition coil 5 Front cylinder ignition coil 6 Sub wire harness 7 ECU engine control unit 8 Turn signal relay 9 Speed s...

Page 391: ...ELECTRICAL COMPONENTS 8 69 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20...

Page 392: ...6 Radiator fan motor fuse 7 Taillight fuse 8 Ignition fuse 9 Signaling system fuse 10 Main fuse 11 Battery 12 Lean angle sensor 13 Starter relay 14 Fuel injection system fuse 15 Relay unit 16 Radiator...

Page 393: ...10 11 8 12 Y G P B R R ON OFF Ch Br W Dg B Y R L R L Y B Y BLACK B B BLACK 13 2 RESET 6 5 7 3 4 1 Br L Br L L B L Y R Y L Y B Y R W B W L W P W Y G B Y P B B R B Y B B Y L Y B Dg Ch Br W BLUE BLACK B...

Page 394: ...switch 2 Rear brake light switch 3 Front brake light switch 4 Reset switch 5 Select switch 6 Engine stop switch 7 Start switch 8 Neutral switch 9 Dimmer switch 10 Turn signal switch 11 Horn switch 12...

Page 395: ...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 sw...

Page 396: ...llowing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled d...

Page 397: ...main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electric...

Page 398: ...hod If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery NOTE Since MF batteries are sealed it is not possible to check the...

Page 399: ...d that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time duri...

Page 400: ...gine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current...

Page 401: ...t starting circuit cut off relay Relay unit fuel pump relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4...

Page 402: ...ster 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 Posi...

Page 403: ...ester 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 contin...

Page 404: ...2 from the wire har ness b Connect the pocket tester 1 to the diode 2 terminals as shown c Check the diode 2 for continuity d Check the diode 2 for no continuity EAS3D81017 CHECKING THE IGNITION SPARK...

Page 405: ...plug lead b Connect the pocket tester 1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni...

Page 406: ...SENSOR 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...

Page 407: ...parks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Ch...

Page 408: ...onnect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the specified horn sound is obtained EAS3D81012 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil lev...

Page 409: ...1 Check Fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warni...

Page 410: ...N c Elevate the rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0...

Page 411: ...specification Replace the throttle position sensor a Connect the pocket tester 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Instal...

Page 412: ...the pocket tester 100 to the air temperature sensor terminal 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 na...

Page 413: ...ELECTRICAL COMPONENTS 8 91...

Page 414: ...LING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PE...

Page 415: ...ose Clogged rollover valve Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Fuel cock Clogged or damaged fuel hose 4 Throttle body ies Deteriorated or...

Page 416: ...S28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar...

Page 417: ...rmostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bol...

Page 418: ...gulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Bu...

Page 419: ...K BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS TAIL BRAKE LIGHT WIRE HARNESS ON OFF L N R RESET...

Page 420: ...7 Horn 48 Turn signal relay 49 Headlight relay 50 Left handlebar switch 51 Dimmer switch 52 Clutch switch 53 Turn signal switch 54 Horn switch 55 Rear right turn signal light 56 Rear left turn signal...

Page 421: ......

Page 422: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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