Yamaha XVS13AW Service Manual Download Page 5 | Manualshive

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EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

3

4

5

6

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2

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Summary of Contents for XVS13AW

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 XVS13AW C XVS13CTW C LIT 11616 20 42 3D8 28197 10 ...

Page 3: ...2006 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 prohibited Printed in U S A P N LIT 11616 20 42 ...

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

Page 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 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 PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 11: ...20140 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 information will be needed to order spare parts 1 1 ...

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

Page 13: ...ontrolled 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 speed sensor and O2 sensor enable the ECU to deter mine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel...

Page 14: ...le 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 switch the display between the odometer mode ODO the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO NOTE Push the side of the SELECT switch to swi...

Page 15: ...n 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 warning light will come on and then the odometer tripmeter clock display will indicate a two digit error code e g 12 13 14 If the odometer tripmeter clock display indicates any error codes note the code ...

Page 16: ...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 a...

Page 17: ...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 18: ...l 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 19: ...d 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 tester 90890 03112 Analog pocket tester YU 03112 C 1 8 5 64 8 73 8 74 8 75 8 79 8 80 8 81 8 82 8 83 8 84 8 85 8 86 8 87 8 88 8 89 8 90 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 5 3 6...

Page 20: ...03 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 driver 36 46 mm YM 01442 4 56 4 57 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 15 5 21 5 22 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 16 Tool name Too...

Page 21: ...243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 33 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 29 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 29 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 29 Tool name Tool No Illustration Reference pages YU 01083 3 ...

Page 22: ...0890 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 clutch holder 90890 04086 YM 91042 5 51 5 55 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 23: ...re 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 gauge 90890 03153 YU 03153 7 11 Fuel pressure adapter 90890 03176 YM 03176 7 11 Tool name Tool No Illustration Reference pages YU 24460 01 YU 33984 ...

Page 24: ...OLS 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 Reference pages ...

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

Page 26: ...TORQUES 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 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 43 ...

Page 27: ...sions 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 clearance 145 mm 5 71 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel XVS13AW C 303 0 kg 668 lb XVS13CTW C 323 0 kg 712 lb Maximum load XVS13AW C 210 kg 463 lb XVS13CTW C 190 kg 419 lb ...

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 Total amount 3 70 L 3 91 US qt 3 26 Imp qt Without oil filter cartridge replacement 3 20 L 3 38 US qt 2 82 Imp qt With oil filter cartridge replacement 3 40 L 3 59 US qt 2 99 Imp qt Oil filter Oil fi...

Page 29: ...dth 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 in Spark plug s Manufacturer model NGK LMAR7A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 44 20 46 40 cm 2 70 2 83 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chai...

Page 30: ...Valve 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 seat width C exhaust 1 00 1 20 mm 0 0394 0 0472 in Valve margin thickness D intake 1 15 1 45 mm 0 0453 0 0571 in Valve margin thickness D exhaust 1 15 1 45 mm 0 0453 0 0571 in Valve stem diameter in...

Page 31: ...8 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 32 lb in 2 52 kgf mm Spring rate K2 exhaust 34 93 N mm 199 45 lb in 3 56 kgf mm Installed compression spring force intake 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Installed compression spring force ...

Page 32: ...5 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 20 4 00 mm 0 05 0 16 in End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 130 mm 0 0051 in Oil ring Dimensions B T 2 ...

Page 33: ...t 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 Plate quantity 8 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring height 6 70 mm 0 26 in Minimum height 6 37 mm 0 25 in Spring quantity 1 pc Clutch housing thrust clearance 0 050 0 450 mm 0 0020 0 0177 ...

Page 34: ...l 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 sensor Resistance 4 0 6 0 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω Intake air pressure sensor output voltage 3 75 4 25 V Coolant temperatur...

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 Manufacturer model BRIDGESTONE EXEDRA G722 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 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 p...

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 left 35 0 Lock to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 135 0 mm 5 31 in Fork spring free length 345 5 mm 13 6...

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 04 in Drive belt Model manufacturer UBD 0734 GATES CORPORATION Drive belt slack on the sidestand 5 0 7 0 mm 0 20 0 28 in Drive belt slack on a suitable stand 4 0 6 0 mm 0 16 0 24 in ...

Page 38: ...o Model 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 Ω Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Manufact...

Page 39: ...80 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 Ω Horn Horn type Plane Quantity 1 pc Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω Performance 108 116 dB 2 m Turn signal relay Relay type Semi transistor Model manuf...

Page 40: ... Fan motor relay Model manufacturer ACM33211 M05 MATSUSHITA Coil resistance 86 40 105 60 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 15 0 A Radiator fan fuse 20 0 A Fuel injection system fuse 10 0 A Backup fuse 10 0 A Reserve fuse 20 0 A Reserve fuse 15 0 A Reserve fuse 10 0 A ...

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

Page 42: ...inder 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 ft lb Timing chain tensioner bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Connecting rod bolt 1st M8 4 15 Nm 1 5 m kg 11 ft lb See NOTE Connecting rod bolt final M8 4 Specified angle 125 135 See NOTE Generato...

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 ft lb O2 sensor M18 1 44 Nm 4 4 m kg 32 ft lb Muffler bracket and frame bolt M10 3 53 Nm 5 3 m kg 38 ft lb Muffler bracket and muffler bolt M10 2 35 Nm 3 5 m kg 25 ft lb Crankcase stud bolt M12 6 15 ...

Page 44: ...m 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 10 Nm 1 0 m kg 7 2 ft lb Front cylinder thermostat inlet pipe 1 bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Front cylinder thermostat inlet pipe 2 bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Rear cylinder thermostat i...

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 tightening sequence B A 1 2 3 4 3 2 1 4 A Front cylinder camshaft assembly B Rear cylinder camshaft assembly 6 5 1 3 2 4 B 3 2 4 6 5 1 A A Front cylinder head B Rear cylinder head ...

Page 46: ...n 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 nut M16 1 85 Nm 8 5 m kg 61 ft lb Relay arm and frame nut M10 1 48 Nm 4 8 m kg 35 ft lb Connecting arm and relay arm nut M12 1 59 Nm 5 9 m kg 43 ft lb Connecting arm and swingarm nut M12 1 59 Nm 5 9 m ...

Page 47: ...6 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 bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front turn signal light bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Front turn signal light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Air temperature sensor screw M5 1 7 Nm 0 ...

Page 48: ...d 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 fender bolt M6 2 11 Nm 1 1 m kg 8 0 ft lb Rear turn signal light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Left side cover bolt M6 1 4 Nm 0 4 m kg 2 9 ft lb Relay cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Sub ...

Page 49: ...6 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 1 ft lb Rectifier regulator bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive pulley nut M22 1 140 Nm 14 0 m kg 100 ft lb Stake Drive pulley cover bolt M6 5 10 Nm 1 0 m kg 7 2 ft lb Drive pulley cover plate bo...

Page 50: ...tors 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 gear inner surface Clutch push rod Oil water pump drive sprocket inner surface Clutch thrust washers Clutch boss nut and washer Transmission gears wheel and pinion and collar Shift forks and shift fork...

Page 51: ...al 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 lever pivoting point and metal to metal moving parts Swingarm pivot bearings inner surface Swingarm pivot oil seals lip Rear shock absorber assembly upper bolt Connecting arm and swingarm collar outer su...

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: ...e 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 Valve stem end intake side 14 Rear cylinder camshaft 15 Front cylinder timing chain tensioner 16 Front cylinder camshaft ...

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: ...COOLING 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 assembly ...

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 cover inlet pipe 10 Radiator inlet hose 11 Radiator 12 Radiator outlet hose 13 Front cylinder thermostat inlet pipe 2 ...

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: ...itch 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 through the guide making sure to route the lead to the outside of the cables C Fasten the starter motor lead securely to the engine mounting boss with a plastic locking tie making sure that the tie does no...

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: ...ont 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 assembly lead and air temperature sensor lead with the plastic band making sure to align the white tape on the wire harness front turn signal light leads and meter assembly lead with the band D Route...

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 20 21 10 22 25 ...

Page 74: ...ose 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 the frame support and then 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 K Fasten the rear brake light switch lead 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: ...hose 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 end of the hose clamp upward as shown in the illustration E Install the brake fluid reservoir hose onto the rear brake master cylinder making sure that the brake pipe touches the projection on the rea...

Page 77: ...ING 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 U 18 19 20 ...

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 positioning tape to the engine mounting boss with a plastic locking tie Position the buckle of the plastic locking tie in front of the boss with the end facing upward and then cut off the excess end of ...

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: ...nward 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 position sensor stator assembly lead ground lead neutral switch lead starter motor lead and rectifier regulator lead with a plastic locking tie making sure to position the tie 10 mm 0 39 in or less to the...

Page 81: ...OUTING 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 R S T U ...

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 Route the fuel sender lead under the air vent hose I Fasten the starter relay lead neutral switch lead and speed sensor lead with a plastic locking tie making sure to position the tie to the inside of ...

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: ...se 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 the rear cylinder intake air pressure sensor hose with its white paint mark facing outward C Route the front cylinder intake air pressure sensor hose and rear cylinder intake air pressure sensor hose ...

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

Page 86: ...purge 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 throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward E 2 4 mm 0 08 0 16 in F Route the canister purge hose California only under the front cylinder inta...

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: ...nk 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 its white paint mark facing downward D Face the crimped section of the hose clamp downward E Install the air vent hose with its paint mark facing upward F Face the ends of the hose clamp upward G In...

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 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE REAR BRAKE PADS 3 21 CHECKING THE FRONT BRAKE HOSES 3 22 CHECKING THE REAR BRAKE ...

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: ...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 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhaust system Check for leakage Tighten if neces...

Page 94: ...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 Engine oil filte...

Page 95: ...ing 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 reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or dama...

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 4 Remove Front cylinder thermostat inlet hose Rear cylinder thermostat inlet hose Refer to THERMOSTAT on page 6 4 5 Disconnect Spark plug caps Refer to ENGINE REMOVAL on page 5 1 6 Remove Spark plug...

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 compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measu...

Page 98: ...ior 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 NOTE Place the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Disconnect Front cylinder intake air pressure sensor hose ...

Page 99: ...h 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 second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION ECA14900 Do not use the throttle valve adjusting...

Page 100: ...r 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 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the...

Page 101: ...ormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Rear cylinder right cover Front cylinder left cover R...

Page 102: ...cyl 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 the engine warm it up for several min utes and then turn it off 3 Remove Front cylinder covers Rear cylinder covers Refer to ENGINE REMOVAL on page 5 1 4 Disconnect Spark plug caps 5 Remove Spark plu...

Page 103: ...ylinder 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 sure the vehicle is upright 2 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil...

Page 104: ...il 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 ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil f...

Page 105: ...he 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 check bolts to specification 13 Install Throttle body Refer to THROTTLE BODIES on page 7 7 Left side cover Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clu...

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 dusty areas 4 Install Air filter element Air filter case cover CAUTION ECA3D81015 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts...

Page 107: ...ir 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 4 Fuel tank overflow hose 5 Cracks damage Replace Loose connection Connect properly CAUTION ECA3D81009 Make sure the fuel tank breather hose and fuel tank overflow hose are routed correctly 3 Instal...

Page 108: ...k 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 vehicle on a suitable stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the...

Page 109: ...t 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 Remove Front cylinder exhaust pipe Refer to ENGINE REMOVAL on page 5 1 2 Check Radiator cover 1 Radiator 2 Radiator inlet hose 3 Radiator outlet hose 4 Radiator outlet pipe 5 Cracks damage Replace Refer t...

Page 110: ...olt 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 brake hose holder 3 7 Remove Coolant reservoir 1 Coolant reservoir cap 2 8 Drain Coolant from the coolant reservoir 9 Install Coolant reservoir 10 Install Rear brake hose holder Rear brake hose guid...

Page 111: ...t 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 the recommended coolant to the maxi mum level mark a 16 Install Coolant reservoir cap 17 Start the engine warm it up for several min utes and then stop it 18 Check Coolant level Refer to CHECKING TH...

Page 112: ...al 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 Adjust the brake pedal adjusting bolt 2 posi tion by turning the adjusting bolt in or out so that its end is visible through the hole c Tighten the locknut 1 to specification WARNING EWA3D81002 A soft...

Page 113: ...inder 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 plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal ...

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 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 o...

Page 115: ...e 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 reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Put the other end of the hose into an open container e Slowly apply the brake several times f Fully pull the brake lever or f...

Page 116: ...t 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 accident Therefore keep the drive belt slack within the specified lim its NOTE Measure the drive belt slack when the engine is cold and when the drive belt is dry 1 Stand the vehicle on a level surfa...

Page 117: ...ts 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 proper wheel alignment d Tighten the locknuts to specification e Tighten the rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 Drive belt slack on the side stand...

Page 118: ...it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 59 e Install the rubber washer 3 f Install the upper ring nut 2 NOTE I...

Page 119: ...NING 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 cylinder exhaust pipe Coolant reservoir cover Refer to ENGINE REMOVAL on page 5 1 2 Disconnect Fuel hose 1 from sub fuel tank Refer to FUEL TANK on page 7 1 3 Adjust Spring preload a Adjust the spring prel...

Page 120: ...ed 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 the tire immediately 2 Check Tire surfaces Damage wear Replace the tire 1 2 3 4 5 6 7 8 9 4 3 a b 1 3 2 Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 ps...

Page 121: ...on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation ...

Page 122: ...ts 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 the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting points and metal to metal moving parts of the rear suspension Recomme...

Page 123: ...ht 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 CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affecte...

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

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 INSTALLING THE FRONT BRAKE CALIPERS 4 30 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 31 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 31 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 31 INSTALLING THE FRON...

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 SHOCK ABSORBER ASSEMBLY 4 65 CHECKING THE CONNECTING ARM AND RELAY ARM 4 66 INSTALLING THE RELAY ARM 4 66 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 66 SWINGARM 4 68 REMOVING THE SWINGARM 4 70 CHE...

Page 128: ......

Page 129: ...move 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 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib ...

Page 130: ...oft 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 Sidebag bracket left and right 2 6 Backrest bracket left and right 2 For installation reverse the removal proce dure R 18 Nm 1 8 m kg 13 ft Ib R 18 Nm 1 8 m kg 13 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R ...

Page 131: ...assenger 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 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 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib ...

Page 132: ...light 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 body 1 For installation reverse the removal proce dure 3 4 2 7 1 8 5 R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 6 ...

Page 133: ...r 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 control unit 1 11 Fuse box 1 12 Main fuse 1 13 Relay unit 1 14 Rear brake fluid reservoir bolt 1 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 13 4 ...

Page 134: ...RAL 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 13 4 ...

Page 135: ...e 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 R 4 Nm 0 4 m kg 2 9 ft Ib New New 1 2 3 5 4 4 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

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 Disconnect 8 Turn signal relay 1 9 Radiator fan motor relay 1 10 Headlight relay 1 11 Relay bracket 1 For installation reverse the removal proce dure 4 1 2 9 8 11 10 7 6 5 R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0...

Page 137: ...rs 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 removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 59 Nm 5 9 m kg 43 ft Ib 6 5 4 6 5 1 3 2 1 6 6...

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: ...t 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 gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check T...

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 adjusted Adjust the front wheel static balance with the brake discs installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the ...

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 stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC The following procedure applies to both of the brake discs 1 Install Front brake disc NOTE Tighten the...

Page 142: ...D81011 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 hoses are routed prop erly T R Front wheel axle 59 Nm 5 9 m kg 43 ft lb Front wheel axle pinch bolt 20 Nm 2 0 m kg 14 ft lb T R Front brake caliper bolt 40 Nm 4 0 m kg 29 ft lb ...

Page 143: ...t 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 Mudguard 1 For installation reverse the removal proce dure 1 2 2 5 4 3 6 T R T R R 23 Nm 2 3 m kg 17 ft Ib 16 Nm 1 6 m kg 11 ft Ib 23 Nm 2 3 m kg 17 ft Ib ...

Page 144: ...d 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 Rear brake caliper bracket 1 12 Collar 1 Black 13 Collar 1 Silver 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 ft Ib T 16...

Page 145: ...oval 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 ft Ib T 16 Nm 1 6 m kg 11 ft Ib 11 8 3 12 14 6 7 13 4 5 9 4 5 10 ...

Page 146: ...Remarks 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 installation reverse the removal proce dure 1 11 2 3 4 9 8 7 6 10 5 LT T R 23 Nm 2 3 m kg 17 ft Ib 6 LS ...

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 New LS 4 6 2 1 ...

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 wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 11 EAS3D81016 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace EAS22110 CHECKING THE REAR WHEEL ...

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 Refer to CHECKING THE REAR BRAKE DISC on page 4 40 4 Install Rear wheel axle Washer Rear wheel axle nut NOTE Temporarily tighten the wheel axle nut 5 Adjust Drive belt slack Refer to ADJUSTING THE DRI...

Page 150: ...of 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 For installation reverse the removal proce dure T R 6 Nm 0 6 m kg 4 3 ft Ib LS 3 1 2 2 4 5 4 6 7 7 T R 27 Nm 2 7 m kg 19 ft Ib 27 Nm 2 7 m kg 19 ft Ib ...

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 Front brake master cylinder holder 1 12 Front brake master cylinder 1 13 Front brake light switch 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...

Page 152: ...bling 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 New 1 2 3 4 ...

Page 153: ...ctor 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 caliper bracket bolt 2 5 Front brake caliper 1 For installation reverse the removal proce dure 1 2 5 3 4 4 T R 30 Nm 3 0 m kg 22 ft Ib R 40 Nm 4 0 m kg 29 ft Ib New ...

Page 154: ...ers 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 Bleed screw 1 For assembly reverse the disassembly pro cedure 6 2 3 4 5 9 1 1 7 8 7 8 T R 27 Nm 2 7 m kg 19 ft Ib R 6 Nm 0 6 m kg 4 3 ft Ib New New LS LS LS LS ...

Page 155: ...dure 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 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...

Page 156: ...astic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw to specification d Install a new brake pad shim new brake pads and a new brake pad spring 3 Lubricate Front brake caliper retaining bolts CAUTION ECA14150 Do not allow grease to c...

Page 157: ...of 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 EWA3D81009 Cover the brake caliper pistons with a rag Be careful not to get injured when the pis ton are expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake ...

Page 158: ...iper 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 page 2 43 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Front brake caliper 3 Install Brake ...

Page 159: ...n 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 bolt 1 Copper washers 2 Front brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER C...

Page 160: ...the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be caref...

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: ...ads 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 1 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib LS ...

Page 163: ...1 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 union bolt 1 9 Copper washer 2 10 Rear brake hose 1 11 Rear brake master cylinder bracket 1 12 Rear brake master cylinder cover 1 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 k...

Page 164: ...he 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 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 3 4 2 5 1 6 7 13 8 10 11 12 9 New LT ...

Page 165: ...inder 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 New LS ...

Page 166: ...efer 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 installation reverse the removal proce dure 4 5 2 3 4 1 R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib New LS ...

Page 167: ...ling 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 Nm 0 6 m kg 4 3 ft Ib LS ...

Page 168: ...alling 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 deflection 1 5 mm 0 06 in below the edge of the brake disc 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING TH...

Page 169: ...BRAKE 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 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 Bra...

Page 170: ...henever 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 CABLE ROUTING on page 2 43 CAUTION ECA14170 When installing the brake hose...

Page 171: ...level 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 to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sy...

Page 172: ...brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage pa...

Page 173: ...d 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 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 kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17...

Page 174: ...oving 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 kg 17 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 9 8 8 7 7 6 6 2 17 11 13 15 14 10 19 11 21 18 18 20 12 16 5 2 1 1 4 3 ...

Page 175: ...e 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 the upper side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE Align the punch mark a on the handlebar with the match ...

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 a on the right handlebar switch with the hole b in the handlebar 8 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Install the front brake master cylinder holder with ...

Page 177: ...efer 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 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in ...

Page 178: ...ge 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 bolt 2 Loosen 7 Cap bolt 1 Loosen 8 Steering stem nut 1 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 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 N...

Page 179: ...g 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 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 110 Nm 11 0 m kg 80 ft lb 1 2 3 1 2 3 4 6 9 8 6 5 10 11 ...

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 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 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New ...

Page 181: ...be 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 T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New ...

Page 182: ...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 183: ...he front fork leg do not allow any foreign ma terial to enter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following ...

Page 184: ...he 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 8 Install Oil seal clip 1 Recommended oil Yamaha fork oil 10WT T R Damper rod bolt...

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 bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Lower front fork cover 1 Front fork leg 2 Upper bracket 3 Temporarily tighten the up...

Page 186: ...TE 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 pinch bolt WARNING EWA13680 Make sure the brake hoses are routed prop erly T R Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Lower front fork cover bolt 18 Nm 1 8 m kg 13 ft lb T R Steering stem ...

Page 187: ...nal 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 inner race 1 14 Upper bearing 1 15 Washer 1 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 Ib R 10 Nm 1 0 m kg 7 2 ft Ib LT LS LS LS T R...

Page 188: ...se 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 Ib R 10 Nm 1 0 m kg 7 2 ft Ib LT LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 10 9 8 7 19 13 14 12 16 15 11 18 19 17 2 1 4 3 5 4 6 LT LT ...

Page 189: ...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 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 on the front brake hose holder with the hole d in the lower bracket 4 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 50 2 c d a 1 b ...

Page 191: ...t 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 absorber assembly lower nut Wash er Bolt Collar 1 1 1 1 4 Rear shock absorber assembly upper nut Bolt 1 1 5 Rear shock absorber assembly 1 6 Relay arm nut Bolt Spacer Collar 1 1 1 1 7 Relay arm 1 LS...

Page 192: ...Bearing 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 6 R 1 1 3 48 Nm 4 8 m kg 35 ft Ib 48 Nm 4 8 m kg 35 ft Ib 59 Nm 5 9 m kg 43 ft Ib LS LS ...

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 ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the ...

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 swingarm and then install the rear shock absorber assembly from between the swingarm and relay arm 4 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut Recommended lubrica...

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: ...nnect 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 Spacer 1 12 Bearing 2 13 Dust cover 2 14 Washer 2 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 61 ft Ib 1 3 2 7 8 4 5 4 5 10 6 9 ...

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 61 ft Ib 1 3 2 7 8 4 5 4 5 10 6 9 14 14 15 16 13 12 12 11 13 16 ...

Page 198: ...the 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 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust covers Spacers Washers Bearings 4 Check Du...

Page 199: ...r 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 in T R Pivot shaft nut 85 Nm 8 5 m kg 61 ft lb T R Rectifier regulator bolt 7 Nm 0 7 m kg 5 1 ft lb a 1 1 2 A B a ...

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 R 10 Nm 1 0 m kg 7 2 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib R 140 Nm 14 0 m kg 100 ft lb 1 2 3 4 ...

Page 201: ...90 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 DRIVE PULLEY 1 Install Drive belt CAUTION ECA14710 Install the drive belt facing the same way...

Page 202: ...pulley 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 BELT SLACK on page 3 24 a 4 3 2 1 ...

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 VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 30 CHECKING THE VALVE SPRINGS 5 31 INSTALLING THE VALVES 5 32 CYLINDERS AND PISTONS 5 34 REMOVING THE PISTONS 5 35 CHECKING THE CYLINDERS AND ...

Page 205: ...ALLING 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 5 61 ELECTRIC STARTER 5 62 CHECKING THE STARTER MOTOR 5 64 ASSEMBLING THE STARTER MOTOR 5 65 CRANKCASE 5 66 DISASSEMBLING THE CRANKCASE 5 70 CHECKING THE CRANKCASE 5 70 CHECKING THE BEARINGS AND OIL ...

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 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 86 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 86 ...

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 Nm 4 4 m kg 32 ft Ib R 35 Nm 3 5 m kg 25 ft Ib R 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib R 53 Nm 5 3 m kg 38 ft Ib New New T R 12 Nm 1 2 m kg 8 7 ft Ib 9 11 2 3 10 6 3 3 R 6 Nm 0 6 m kg 4 ...

Page 208: ...XHAUST 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 pipe cover screw clamp 6 Nm 0 6 m kg 4 3 ft lb New ...

Page 209: ...d 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 cover 1 12 Ground lead 1 Disconnect 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 ...

Page 210: ...Job 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 ft Ib LT R 8 Nm 0 8 m kg 5 8 ft Ib R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib 1 2 10 11 13 12 6 7 3 4 5 8 9 5 ...

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 punch mark b in the shift arm 2 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 24 T R Cylinder cover bolt 8 Nm 0 8 m kg 5 8 ft lb T R Shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb 2 1 4 ...

Page 212: ...ly 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 coil coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Speed sensor coupler 1 Disconnect 7 Neutral switch coupler 1 Disconnect 8 Neutral switch connector 1 Disconnect 9 Horn con...

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: ...1 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 Engine mounting bolt front left upper side 2 17 Engine mounting bolt front right upper side 2 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...

Page 215: ...ngine 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 Ib R 48 Nm 4 8 m kg 35 ft Ib R 88 Nm 8 8 m kg 64 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 5 1 2 6 5 4 3 18 11 9 8 10 13 15 17 20 19 4 16 14 12 7 6 ...

Page 216: ...r 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 bolts rear upper side down tube bolts front side and down tube bolts rear side Do not tighten the bolts and nuts 3 Tighten Engine bracket bolts rear lower side 7 Engine bracket bolts rear upper side...

Page 217: ...ide 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 Engine mounting nut rear lower side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut rear upper side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut front lower side 88 Nm 8 8 m kg 64 ft lb 13 11 4 16 5 ...

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 head cover 1 12 Cylinder head cover gasket 2 13 Dowel pin 4 For installation reverse the removal proce dure 1 8 6 8 7 9 7 6 6 1 11 12 13 13 1 4 3 2 5 2 3 3 1 4 10 12 13 13 New New New New New New R 10...

Page 219: ...ng 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 dure FWD 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 R 10 Nm 1 0 m kg 7 2 ft Ib E E T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m k...

Page 220: ...Valve 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 1 10 Camshaft carrier 1 For installation reverse the removal proce dure EX IN EX IN E E M T R 14 Nm 1 4 m kg 10 ft Ib R 14 Nm 1 4 m kg 10 ft Ib M New 1 1 2 2 3 5 8 9 7 4 6 2 10 1 2 1 ...

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 is mounted 3 Remove Front cylinder camshaft sprocket NOTE While holding the camshaft sprocket with the rotor holding tool 1 loosen the camshaft sprocket bolts 2 To prevent the timing chain from fall...

Page 222: ...tensioner 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 front cylinder camshaft assembly EAS3D81034 REMOVING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts 1 Remove Intake rocker arm shaft Exhaust rocker ...

Page 223: ...plies 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 check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace Camshaft lobe dimensions Intake A 42 988 43 088 mm 1 6924 1 6964 in Limit 42 888 mm 1 6885 in Intake B 3...

Page 224: ...chain 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 housing a Install the timing chain tensioner outer spring timing chain tensioner clip 2 1 and clip 1 2 NOTE Be sure to face the ends of timing chain tension er clip 2 1 in the direction shown in the il...

Page 225: ...INSTALLING 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 in the illustra tion so that the camshaft lobes will not catch on the camshaft carrier during installation Position the opening between the ends of the circlip in the 90 range a shown in the illustra...

Page 226: ...stroke 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 onto the camshaft and then finger tighten the camshaft sprocket bolts 3 CAUTION ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing NOTE To posit...

Page 227: ...k 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 camshaft assembly 1 NOTE Be sure to install the camshaft assembly without a punch mark onto the rear cylinder 7 Tighten Rear cylinder camshaft assembly bolts NOTE Tighten the bolts in the proper sequenc...

Page 228: ...shaft 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 camshaft sprocket be sure to keep the timing chain as tight as possible on the intake side d Remove the wire from the timing chain 9 Tighten Rear cylinder camshaft sprocket bolts 1 NOTE While holding the...

Page 229: ...lts 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 55 mm 2 17 in T R Rear cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb A Intake side B Exhaust side 2 a 1 New 3 A B 4 3 2 1 3 4 2 3 T R Front cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb A Inta...

Page 230: ...1 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 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib 65 Nm 6 5 m kg 47 ft Ib R 13 Nm 1 3 m kg 9 4 ft Ib R 13 Nm 1 3 m kg 9 4 ft Ib FWD 2 1 4 4 3 5 1 5 New New 4 4 New E E New E E E E ...

Page 231: ...g Spark plug bore threads Valve seats 2 Check Cylinder heads Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place 400 600 grit wet sandpaper on a sur face plate and resurface th...

Page 232: ...ne 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 9 4 ft lb A Front cylinder head B Rear cylinder head 3 2 4 6 5 1 A 6 5 1 3 2 4 B ...

Page 233: ...ure 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 spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure New New New New M M M M M M E E 1 1 2 2 6 6 3 3 7 7 7 7 8 8 8 8 1 1 2 2 6 6 3 3 4 5 ...

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 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 VALVES AND VALVE GUIDES The fo...

Page 235: ...tem 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 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position 14 5 14 9 mm 0 571 0 587 ...

Page 236: ...m 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 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 Wh...

Page 237: ...th 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 the valve through the valve guide and onto the valve seat to make a clear ...

Page 238: ...lve 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 38 44 44 29 lbf 17 44 20 09 kgf Installed compression spring force exhaust 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Installed length intake 35 00 mm 1 38 in Installed length exhaust 35 00 mm 1 38 in ...

Page 239: ...he valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor att...

Page 240: ...NDER 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 11 2nd ring 2 12 Oil ring 2 For installation reverse the removal proce dure New New New New New New E E E FWD 1 2 4 6 6 3 5 6 10 11 12 7 9 9 7 7 7 8 8 1 10 11 12 ...

Page 241: ...en 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 Measure the cylinder b...

Page 242: ...ng 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 piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring in the cylinder with the pis ton crown Piston Diameter D 99 955 99 970 mm 3 9352 3 9358 in b 8 mm 0 31 in from the botto...

Page 243: ...b 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 gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 027...

Page 244: ...e 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 that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Off...

Page 245: ...AND 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 chain cavity 1 ...

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 Disconnect 3 Damper cover 1 4 Generator cover damper 1 5 Left side cover bracket 1 6 Generator cover 1 7 Generator cover gasket 1 8 Dowel pin 2 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...

Page 247: ...on 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 Nm 0 6 m kg 4 3 ft Ib New New New LS LS LS LT LT T 10 Nm 1 0 m kg 7 2 ft Ib LT 9 10 8 8 7 11 5 2 1 4 3 6 6 New E 12 ...

Page 248: ...e 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 reverse the removal proce dure 6 LT 1 6 7 5 4 3 2 T R 24 Nm 2 4 m kg 17 ft Ib R 90 Nm 9 0 m kg 65 ft Ib E E E E E ...

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 rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clut...

Page 250: ...TE 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 tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the generator...

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: ...Drain 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 Clutch cover gasket 1 9 Dowel pin 2 For installation reverse the removal proce dure New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 3 4 5 6 7 8 9 9 6 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 2 New 1 3 LS ...

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 damper spring 1 15 Clutch damper spring seat 1 16 Clutch boss 1 17 Thrust washer 1 1 E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New New E LS 23 22 21 20 T R 8 Nm 0 8 m kg 5 8 ft Ib E E E LT 2 6 3 T ...

Page 255: ...r 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 New E LS 23 22 21 20 T R 8 Nm 0 8 m kg 5 8 ft Ib E E E LT 2 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 125 Nm 12 5 m kg 90 ft lb E ...

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 Primary drive gear nut 1 5 Lock washer 1 6 Spacer 1 7 Primary drive gear 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib R 100 Nm 10 0 m kg 72 ft lb New New New E R 10 Nm 1 0...

Page 257: ...y 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 generator rotor EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Fricti...

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 clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting...

Page 259: ...pinion 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 damage wear Replace the oil wa ter pump drive chain and oil water pump drive and driven sprockets as a set 2 Check Oil water pump drive chain Damage stiffness Replace the oil water pump drive chain and oi...

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 sure that the primary drive gear 2 and clutch hous ing primary driven gear 3 are aligned as shown in the illustration 3 Install Clutch boss assembly 1 NOTE Install the clutch damper spring 2 with the ...

Page 261: ...n 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 Clutch spring plate retainer NOTE Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip NOTE Make sure that the m...

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: ...VE 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 Shift shaft spring 1 7 Shift shaft spring stopper 1 For installation reverse the removal proce dure LS New E 7 LT 1 6 5 4 3 2 New E R 22 Nm 2 2 m kg 16 ft Ib ...

Page 264: ...ughly 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 the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum seg ment assembly Hook the end of the shift shaft spring onto the shift ...

Page 265: ...y 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 proce dure R 12 Nm 1 2 m kg 8 7 ft Ib LT R 12 Nm 1 2 m kg 8 7 ft Ib LT E LT 2 1 3 ...

Page 266: ...ove 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 proce dure 1 2 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New E ...

Page 267: ...ly 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 LEFT BALANCER GEARS 1 Install Left balancer assembly 2 Install Left balancer drive gear 1 NOTE Align the punch mark a in the left balancer driven gear with the punch mark b in the left balancer drive g...

Page 268: ...TRIC 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 ft Ib R 10 Nm 1 0 m kg 7 2 ft Ib 2 1 ...

Page 269: ...her 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 holder bracket 1 14 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 2 6 5 4 7 10 10 14 9 8 13 12 11 New New New New New LS E 3 1 LS New ...

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 starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica ...

Page 271: ...G 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 cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers 1 a b a b 1 3 b 2 ...

Page 272: ...guide 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 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 T R 17 Nm 1 7 m kg 12 ft Ib R 70 Nm 7 0 m kg 50 ft lb T R 15 Nm 1 5 m kg 11 ft Ib R 20 Nm 2 0 m kg 14...

Page 273: ...ob 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 T R 17 Nm 1 7 m kg 12 ft Ib R 70 Nm 7 0 m kg 50 ft lb T R 15 Nm 1 5 m kg 11 ft Ib R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib R 20 Nm 2 0 m kg 14 ft Ib New New New New New New New New New ...

Page 274: ...Joint 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 R 10 Nm 1 0 m kg 7 2 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT LT New New New New New LS LS LT LS LS 1 5 2 3 19 7 3 4 5 6 8 ...

Page 275: ...n 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 proce dure New LT LS LT LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib LT E New LS E E New LS E 1 1 3 2 3 3 3 3 4 4 ...

Page 276: ...pressed 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 Replace EAS25600 CHECKING THE OIL DELIVERY PIPES AND COOLANT DELIVERY PIPE The following procedure applies to all of the oil delivery pipes and joint pipe 1 Check Oil delivery pipe Joint pipe Damage 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 a soft face hammer 4 Install Crankcase bolts M10 Crankcase bolts M6 NOTE Apply locking agent LOCTITE to the threads of the bolts 2 Tighten each bolt 1 4 of a turn at a time in stag es and in a criss...

Page 278: ...KCASE 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 3 B ...

Page 279: ...p 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 removal proce dure R 10 Nm 1 0 m kg 7 2 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 R 24 Nm 2 4 m kg 17 ft Ib R 24 Nm 2 4 m kg 17 ft Ib LS 8 8 6 9 10 11 12 7 4 5 1 2 3 New New New New Ne...

Page 280: ...operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage wear 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 Outer rotor to oil pump housing clearance 0 09 0 19 mm 0 0035 0 0075 in Limit 0 26 ...

Page 281: ...installing 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 WATER PUMP ASSEMBLY 1 Install Oil water pump assembly CAUTION ECA3D81020 After tightening the bolts make sure the oil water pump assembly turns smoothly Recommended lubricant Engine oil T R Oil pump ...

Page 282: ...kcase 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 dure E E M M M M New New New E T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd Specified angle 125 135 1 2 3 4 5 4 2 3 ...

Page 283: ...plies 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 pin and the inside of the connecting rod halves b Install the big end upper bearing in...

Page 284: ...r 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 placement big end bearings 4 Select Big end bearings P1 P2 NOTE The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bear...

Page 285: ...ecommended 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 crankshaft pin NOTE Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make...

Page 286: ...hen 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 to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly CAUTION ECA3D81013 To avoid sc...

Page 287: ...s 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 axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure New LS E E E 2 4 5 1 3 6 4 7 ...

Page 288: ...rts 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 reverse the disassembly pro cedure New New New M M 1 2 3 4 5 6 7 8 9 ...

Page 289: ...th 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 1 14 Circlip 1 15 Dog clutch 1 16 Circlip 1 17 Toothed washer 1 New New New M M M M M M M 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 290: ...ar 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 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 291: ...h movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a cent...

Page 292: ...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 ...

Page 293: ...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 4 1 2 3 5 ...

Page 294: ...ING 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 PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 ...

Page 295: ...COOLANT 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 1 8 Radiator cap 1 9 Radiator fan motor coupler 1 Disconnect 10 Radiator cover 1 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 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R...

Page 296: ...diator 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 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 New New T R 2 Nm 0 2 m kg 1 4 ft Ib LT LT 2 1 6 5 4 7 12 10 13 16 14 15 11 9 8 3 3 ...

Page 297: ...nd make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 17 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure B...

Page 298: ...t 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 temperature sensor 1 7 Radiator filler pipe 1 8 Thermostat cover inlet hose 1 9 Thermostat bracket 1 10 Thermostat cover assembly 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 kg 7...

Page 299: ...inder 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 1 0 m kg 7 2 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 R 7 Nm 0 7 m kg 5 1 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New New LT LT LT 5 1 2 3 6 4 7 12 10 13 16 17 18 14 15 11 9 8...

Page 300: ...g 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 THERMOSTAT ASSEMBLY 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COO...

Page 301: ...rankcase 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 damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 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 LS 5 New New New New New LS LS LS New L...

Page 302: ...erse 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 LS 5 New New New New New LS LS LS New LS 3 1 2 2 10 6 7 8 9 4 ...

Page 303: ...r 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 housing NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 CAUTION ...

Page 304: ...090 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 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1215 90890 85505 Three Bond No 1215 A Push down 4 Mechanical seal installer 5 Middle driven shaft bearing driver New New Impeller shaft tilt limit ...

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

Page 306: ...TION 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 THROTTLE BODIES 7 11 CHECKING THE FUEL PRESSURE 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 INSTALLING THE INTAKE MANIFOLD ASSEMBLY 7 12 ...

Page 307: ...el 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 tank to hose joint 1 9 Fuel tank 1 10 Fuel sender 1 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 New 5 6 1 9 2 3 10 11 7 8 1 New New Ne...

Page 308: ...everse 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 New 5 6 1 9 2 3 10 11 7 8 1 New New New New New 4 ...

Page 309: ...r 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 reverse the removal proce dure 4 5 6 3 1 2 New R 10 Nm 1 0 m kg 7 2 ft Ib 3 3 3 6 T R 6 Nm 0 6 m kg 4 3 ft Ib ...

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 to rollover valve 1 5 Rollover valve 1 6 Canister 1 California only 7 Canister breather hose 1 California only For installation reverse the removal proce dure 3 2 4 5 6 7 LT R 7 Nm 0 7 m kg 5 1 ft I...

Page 311: ...removed 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 Obstruction clean Blow out the jets with compressed air Damage Replace EAS26660 CHECKING THE FUEL COCK OPERATION NOTE After installing the fuel cock check its operation 1 Check Fuel cock operation O...

Page 312: ...ected 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 until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown EAS3D81040 INSTALLING THE FU...

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 cable 2 Disconnect 6 ISC idle speed control unit coupler 1 Disconnect 7 Throttle body 1 CAUTION ECA3D81003 The throttle body should not be disas sembled 8 Gasket 1 9 ISC idle speed control unit 1 2 4...

Page 314: ...tle 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 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 315: ...t 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 manifold joint clamp screw 2 Loosen 9 Rear cylinder intake manifold joint 1 10 Intake manifold assembly 1 11 Front cylinder intake manifold joint 1 For installation reverse the removal proce dure R 1...

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 disassembly pro cedure R 10 Nm 1 0 m kg 7 2 ft Ib New New New New 4 6 4 4 2 1 3 5 ...

Page 317: ...ing 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 Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle p...

Page 318: ...Install 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 Make sure that the projection b on the rear cyl inder intake manifold joint contacts the projec tion c on the intake manifold assembly c Install the intake manifold assembly NOTE Lubricate the rear cy...

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

Page 320: ...RAM 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 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 SELF DIAGNOSTIC FUNCTION TABLE 8 34 TROUBLESHOOTING METHOD 8 36 DIAGNOSTIC MODE 8 37 TROUBLESHOOTIN...

Page 321: ...TION 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 OIL LEVEL SWITCH 8 86 CHECKING THE FUEL SENDER 8 87 CHECKING THE FUEL LEVEL WARNING LIGHT 8 87 CHECKING THE OIL LEVEL WARNING LIGHT 8 88 CHECKING THE SPEED SENSOR 8 88 CHECKING THE RADIATOR FAN MOTOR 8...

Page 322: ......

Page 323: ...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 HARNESS TA L BRAKE L GHT W RE HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L Br Y Y L Y L B Br Y B G C C B B C B W B R R Br W B R B R B R R L W R W R...

Page 324: ...ttery 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 Spark plug 65 Engine stop switch 73 Ignition fuse ...

Page 325: ...eventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch is open 1 4 5 10 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch ...

Page 326: ...age 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 gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 82 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 83 Replace the spark plug cap s 6 Check the...

Page 327: ...SWITCHES 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 THE DI ODES on page 8 81 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 84 Replace the lean angle sensor 14 Check the entire ignition system s ...

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

Page 329: ...UE 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 C C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y L Y G L G L G L P W Y G L R B Y P B R W L W B R Y B R Y Br B Y G Y B L P W L B L B L Br W G W B L B L Y G L P L B L Y L B R B L L W B ...

Page 330: ...use 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 switch 66 Start switch 73 Ignition fuse ...

Page 331: ...is 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 of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the start...

Page 332: ...E 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 switch 10 Sidestand switch 11 Neutral switch 12 Diode 1 13 Starter relay 14 Start switch 15 Starter motor ...

Page 333: ...minals 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 troubleshooting start ing with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 64 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay...

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 SWITCHES on page 8 71 Replace the sidestand switch 14 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 71 Replace the clutch switch 15 Check the start switch Refer to CHECKING THE SWITCHE...

Page 335: ...Y 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 R Y B Ch L B Y B B B Y L R L Br Y Y L Y L B Br Y B G C C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y L Y G L G L G L P W Y G L R B Y P B R W L W B R Y B R Y Br B Y Ch G Y B L P W L ...

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 crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 85 Replace the rectifier regulator 5 Check the entire charging system s wirin...

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

Page 339: ...ACK 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 HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B L Br Y L Y L B Br B G C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y R W L B Gy W Y Gy ...

Page 340: ...er 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 plate light 68 Tail brake light 72 Headlight fuse 73 Ignition fuse 74 Signaling system fuse 75 Taillight fuse ...

Page 341: ...CKETS 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 battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 75 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 71 Replac...

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: ...K 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 HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B L Br Y L Y L B Br B G C C C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y R W L B Gy W Y Gy...

Page 344: ...tral 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 Horn switch 55 Rear right turn signal light 56 Rear left turn signal light 57 Front right turn signal light 58 Front left turn signal light 62 Front brake light switch 68 Tail brake light 70 Rear br...

Page 345: ...5 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 THE SWITCHES on page 8 71 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Check the c...

Page 346: ...front 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 rear brake light switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the turn si...

Page 347: ...the 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 entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING T...

Page 348: ...ing 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 system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Replace the ECU or meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED ...

Page 349: ...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 WIRE HARNESS SUB W REHARNESS B WIRE HARNESS SUB W REHARNESS C WIRE HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B L Br Y L Y L B Br B G C C C B B B W B R R Br W B R B R B R R L W R W R W L W B L L W Y R W L B Gy W Y Gy R ...

Page 350: ...OLING 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 fuse ...

Page 351: ...minals 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 MOTOR on page 8 88 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 79 Replace the radiator fan motor relay 6 Check the coolant temperature sen...

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

Page 353: ...Y 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 HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B L Br Y L Y L B Br B G C C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y R W L B Gy W ...

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 coil 30 Spark plug 31 ISC idle speed control unit 32 Front cylinder injector 33 Rear cylinder injector 38 Multi function meter 39 Engine trouble warning light 46 O2 sensor 49 Headlight relay 63 Select ...

Page 355: ...dometer 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 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...

Page 356: ...ble 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 open or short circuit Front cylinder intake air pressure sensor open or short circuit de tected Able Able 14 Front cylinder intake air pressure sensor hose system Front cylinder intake air pressure se...

Page 357: ...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 or short circuit is detected in the neutral switch 43 Fuel system voltage monitoring voltage The ECU is unable to monitor the battery voltage an...

Page 358: ...ng 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 If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal mal...

Page 359: ...tic 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 To decrease the selected diagnostic code number press the side of the SELECT switch Press the side of the SELECT switch for 1 second or longer to automatically decrease the diagnostic code numbers To ...

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 harness ECU coupler Malfunction in ECU 20 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Imp...

Page 361: ...tion 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 speed sen sor Open circuit is detected in the neutral switch Open circuit in wire harness Defective speed sensor Malfunction in speed sensor detected Defective neutral switch Malfunction in the engine ...

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 cylinder 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 rear cylin...

Page 363: ...r 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 gear OFF 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...

Page 364: ...park 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 operating sound of the front cylinder injector five times 37 Rear cylinder injector Actuates the rear cylinder in jector five times at one sec ond intervals Illuminates the engine trou ble warning li...

Page 365: ...7 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 fan motor Check the operating sound of the radiator fan motor re lay five times 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates t...

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 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 367: ...he 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 Repair or replace if there is an open or short circuit Between front cylinder intake air pressure sensor coupler and ECU coupler black blue black blue pink pink blue blue...

Page 368: ...Starting 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 malfunc tion 3 Connections Front cylinder intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler I...

Page 369: ...heck 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 throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sensor lead open cir cuit output voltage check Check for open circuit ...

Page 370: ...ive 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 components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tempera ture sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Coo...

Page 371: ...temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between air temperature sensor coupler and ECU coupler brown white brown white black b...

Page 372: ...nsor 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 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 white red white gray black gray ...

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 circuit in wire harness Repair or replace if there is an open or short circuit between rear cylinder intake air pres sure sensor coupler and ECU coupler black blue black blue pink white pink white blue bl...

Page 374: ...there 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 THE IN TAKE AIR PRESSURE SEN SORS on page 8 89 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 ...

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 harness Repair or replace if there is an open or short circuit Between front cylinder ignition coil connector and ECU cou pler orange orange Between front cylinder ignition coil connector and right handl...

Page 376: ...ocking 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 rear cylinder ignition coil connector and ECU cou pler gray red gray red Between rear cylinder ignition coil connector and right handl...

Page 377: ...ine 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 continuously being transmitted by the ECU Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is turned to OFF Touch the ISC unit...

Page 378: ...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 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 senso...

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 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 blue A 3...

Page 380: ...y 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 81 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on p...

Page 381: ...d 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 right handlebar 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 with...

Page 382: ...unction 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 and main fuse red red Between main fuse and main switch coupler black red red Between main switch coupler and ignition fuse brown brown Between ignition fuse and ECU coupler red white red white Faul...

Page 383: ...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 Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that ma...

Page 384: ...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 Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that may ...

Page 385: ...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 HARNESS Gy R ON OFF L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B L Br Y L Y L B Br B G C C C B B C B W B R R Br W B R B R B R R L W R W R W L W B L L W Y R W L B Gy W Y Gy R...

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: ...ND 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 engine stop switch Refer to CHECKING THE SWITCHES on page 8 71 The engine stop switch is faulty Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAY...

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: ...ke 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 sensor 10 Neutral switch 11 Oil level switch 12 Horn 13 Air temperature sensor ...

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 fan motor relay 17 Headlight relay 18 Sidestand switch 19 Rear brake light switch 20 Radiator fan motor ...

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 Y P G Y R R Y B Y Y G B W B P W P B R W B R Br L W L Y L B Br 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 Clutch switch 13 Sidestand switch ...

Page 395: ...1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch posi...

Page 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 down CAUTION ECA3D81021 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the...

Page 397: ...e main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri c...

Page 398: ...thod 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 charge state of the battery by mea suring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rid...

Page 399: ...nd that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a...

Page 400: ...ngine 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 is lower than the standard charging current written on the battery this type of battery charger cannot charge the MF battery A vari able voltage charger is recommended d Charge the battery until the...

Page 401: ...nit 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 Negative tester probe Result Continuity between 3 and 4 R B R 2 1 4 3 L w 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity be...

Page 402: ...ester 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 R Y G L Br Y B 1 2 3 4 L 1 ...

Page 403: ...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 blue white 4 No continuity Positive tester probe sky bl...

Page 404: ...e 2 from the wire har ness b Connect the pocket tester Ω 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 GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 Pocket tester 90890 03112 Analog pocket t...

Page 405: ...ug lead b Connect the pocket tester Ω 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 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...

Page 406: ...E 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 to the lean angle sensor coupler as shown Secondary coil resistance 8 64 12 96 k Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black red 1 Negative tester probe s...

Page 407: ...arks 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 Check Stator coil resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil res...

Page 408: ...nnect 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 level switch from the crankcase 3 Check Oil level switch resistance Out of specification Replace the oil level switch Charging voltage 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU ...

Page 409: ...t 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 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 Pocket tester 90890 03112 Analog po...

Page 410: ...ON 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 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect a battery D...

Page 411: ...specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor NOTE When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 11 EAS28410 CHECKING THE INTAKE AIR ...

Page 412: ...the pocket tester Ω 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 nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water and then let it cool down to the specified temperature e Measure the air temperature sensor resis tance Pocket tester 90...

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

Page 414: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 415: ...hose 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 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 g...

Page 416: ...AS28540 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 Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly ret...

Page 417: ...ermostat 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 bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or...

Page 418: ...egulator 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 Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal do...

Page 419: ...CK 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 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 30 30 29 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 71 70 72 73 74 75 56 57 58 59 61 62 63 6...

Page 420: ...47 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 light 57 Front right turn signal light 58 Front left turn signal light 59 Headlight 60 Accessory light OPTION 61 Right handlebar switch 62 Front brake light switch 63 Select switch 64 Reset switch 65...

Page 421: ......

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

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