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Yamaha XVS950CU 2014, Service Manual


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CAMSHAFTS

5-16

EAS23740

CAMSHAFTS

Removing the cylinder head covers

Order

Job/Parts to remove

Q’ty

Remarks

Air filter case

Refer to “GENERAL CHASSIS” on page 
4-1.

Cylinder covers/Cylinder cover brackets/Rear 
cylinder head guard

Refer to “ENGINE REMOVAL” on page 5-3.

Fuel tank/Hose holder

Refer to “FUEL TANK” on page 6-1.

Throttle body/Intake manifold assembly

Refer to “THROTTLE BODIES” on page 6-6.

1

Tappet cover

4

2

O-ring

4

3

Fuel filter bracket

1

4

Front cylinder side cover

1

5

Front cylinder side cover gasket

1

6

Rear cylinder side cover

1

7

Rear cylinder side cover gasket

1

For installation, reverse the removal proce-
dure.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R.

FWD

FW

D

LT

LT

LS

LS

New

1

2

New

2

New

7

New

2

New

2

6

1

3

1

1

New

5

4

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

.

(5)

(5)

(5)

(5)

(5)

Summary of Contents for XVS950CU 2014

Page 1: ...2014 SERVICE MANUAL XVS950CU XVS950CUE 1XC 28197 E0...

Page 2: ...VS950CUE 2014 SERVICE MANUAL 2014 by Yamaha Motor Co Ltd First edition November 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is e...

Page 3: ...ificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are...

Page 4: ...b section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section...

Page 5: ...N SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease...

Page 6: ......

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

Page 8: ......

Page 9: ...9 ABS OPERATION 1 15 ABS WARNING LIGHT AND OPERATION 1 18 INSTRUMENT FUNCTIONS 1 19 IMPORTANT INFORMATION 1 21 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 21 REPLACEMENT PARTS 1 21 GASKETS OIL SEALS AN...

Page 10: ...E IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the rider seat...

Page 11: ...and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically contr...

Page 12: ...sor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor lean angle sensor speed sensor except for ABS models rear wheel sen sor for ABS models and O2...

Page 13: ...c maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 2 3 4 6 7 8 9 10...

Page 14: ...occurs between the tires and the road surface This causes a difference between the wheel speed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the...

Page 15: ...eel speed reduction rate exceed the preset values the ABS ECU de termines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figur...

Page 16: ...ys WARNING EWA1XC1004 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of t...

Page 17: ...lso includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning ligh...

Page 18: ...and are installed close to the wheel sensors As the sensor rotor rotates the hall element in the hall IC installed in the wheel sensor generates the voltage which is proportional to the magnetic flux...

Page 19: ...vicing are completed the ABS warning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mph or faster NOTICE ECA1XC1002 If the rear wheel is raced with the vehicle on a suit...

Page 20: ...is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet sol...

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

Page 22: ...lfunction is detected in the ABS a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19...

Page 23: ...tch was turned on During this test a clicking noise can be heard from under the seat and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but...

Page 24: ...e brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the orific...

Page 25: ...utlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped bac...

Page 26: ...As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brak...

Page 27: ...to shorten the braking distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore...

Page 28: ...odes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 clock ODO If the fuel level warning light comes on the odometer display will automatically change to the fuel reserve...

Page 29: ...em indicator light will flash and the display will indicate a fault code TIP If the display indicates fault code 52 this could be caused by transponder interference If this fault code appears try the...

Page 30: ...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...

Page 31: ...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 on...

Page 32: ...tener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fast...

Page 33: ...a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Re...

Page 34: ...5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never i...

Page 35: ...refore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely an...

Page 36: ...most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuri...

Page 37: ...TIP 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 poc...

Page 38: ...amper rod holder 22 mm 90890 01365 4 80 4 82 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 80 4 82 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 82 4 82 4 83 Fork...

Page 39: ...ammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 20 Weight 90890 01084 YU 01083 3 5 20 Valve spring compressor 90890 04019 YM 04019 5 30 5 35 Valve spring compressor attachment 90890 01243 V...

Page 40: ...0 mm YM 04066 5 31 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 37 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 45 5 45 5 46 5 46 5 53 5 58 Flywheel puller 90890 013...

Page 41: ...pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 6 10 Pressure gauge 90890 03153 YU 03153 6 10 Fuel pressure adapter 90890 03176 YM 03176 6 10 Test harness TPS 3P 90890 03204 YU 03204 6...

Page 42: ...SPECIAL TOOLS 1 33 Test harness S pressure sensor 3P 90890 03207 YU 03207 7 167 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 7 168 Tool name Tool No Illustration Reference pages...

Page 43: ...NERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART...

Page 44: ...S950CUE 2DX5 AUS except for ABS models Dimensions Overall length 2290 mm 90 2 in Overall width 830 mm 32 7 in Overall height 1120 mm 44 1 in Seat height 690 mm 27 2 in Wheelbase 1570 mm 61 8 in Ground...

Page 45: ...10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 4 30 L 4 55 US qt 3 78 Imp qt Without oil filter c...

Page 46: ...ing chain Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside diameter 11 981 11 991...

Page 47: ...012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025...

Page 48: ...0 0012 0 0022 in Limit 0 15 mm 0 0059 in Diameter D 84 955 84 970 mm 3 3447 3 3453 in Height H 8 0 mm 0 31 in Offset 0 50 mm 0 0197 in Piston pin bore inside diameter 21 004 21 015 mm 0 8269 0 8274 in...

Page 49: ...h A 97 95 98 00 mm 3 856 3 858 in Runout limit C 0 020 mm 0 0008 in Big end side clearance D 0 320 0 474 mm 0 0126 0 0187 in Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack...

Page 50: ...pump Pump type Electrical Maximum consumption amperage 2 0 A Fuel injector Model quantity 1450 2 Resistance 12 0 Throttle body Type quantity ACW35 1 ID mark 1TP1 00 Fuel line pressure at idling 220 3...

Page 51: ...ENGINE SPECIFICATIONS 2 8 Oil temperature 60 0 70 0 C 140 00 158 00 F Throttle grip free play 4 0 6 0 mm 0 16 0 24 in...

Page 52: ...ss Size 100 90 19M C 57H Manufacturer model BRIDGESTONE EXEDRA G721 Wear limit front XVS950CU 1 6 mm 0 06 in XVS950CUE 1 0 mm 0 04 in Rear tire Type Tubeless Size 150 80B16M C 71H Manufacturer model B...

Page 53: ...e pad lining thickness inner 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder i...

Page 54: ...r models equipped with gas cylinders Spring installed length 159 7 mm 6 29 in for models not equipped with gas cylinders 120 5 mm 4 74 in for models equipped with gas cylinders Spring rate K1 37 30 N...

Page 55: ...or type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Manufacturer GS YUASA Ten ho...

Page 56: ...orn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal hazard relay Relay type Semi transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Minimu...

Page 57: ...ELECTRICAL SPECIFICATIONS 2 14 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 30 0 A for ABS models...

Page 58: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque speci...

Page 59: ...olt M8 2 20 Nm 2 0 m kgf 14 ft lbf Rear cylinder right cover bracket bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Shift arm pinch bolt M6 1 16 Nm 1 6 m kgf 12 ft lbf Tappet cover bolt M6 18 10 Nm 1 0 m kgf 7 2...

Page 60: ...bracket bolt M10 2 35 Nm 3 5 m kgf 25 ft lbf Muffler protector 1 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector 2 M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Muffler protector inner M6 3 8 Nm 0 8 m kgf 5 8 ft lb...

Page 61: ...2 bolt M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Starter clutch bolt M8 3 24 Nm 2 4 m kgf 17 ft lbf Primary drive gear nut M18 1 100 Nm 10 m kgf 72 ft lbf Use a lock washer Clutch boss nut M20 1 125 Nm 12 5 m...

Page 62: ...o 65 Nm 6 5 m kgf 47 ft lbf Front cylinder head Rear cylinder head TIP Connecting rod bolt Tighten the connecting rod bolts to 15 Nm 1 5 m kgf 11 ft lbf and then tighten them further to reach the spec...

Page 63: ...ighten the generator cover bolts in the order shown in the illus tration TIP Clutch cover bolt Temporally tighten the bolts a and b and then tighten the clutch cover bolts in the order shown in the il...

Page 64: ...gnition coil bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Ignition coil bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable locknut crankcase side M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Rectifier regulator bracke...

Page 65: ...orque M25 1 52 Nm 5 2 m kgf 38 ft lbf See TIP Lower ring nut final tightening torque M25 1 18 Nm 1 8 m kgf 13 ft lbf See TIP Lower bracket pinch bolt M10 4 23 Nm 2 3 m kgf 17 ft lbf Front fork damper...

Page 66: ...ft lbf Tail brake light and rear fender nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate bracket and rear fender bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf License plate light nut M5 2 3 8 Nm 0 38 m kgf 2 8...

Page 67: ...t M8 2 23 Nm 2 3 m kgf 17 ft lbf Rear brake hose guide bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose union bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Rear brake hose holder bolt M6 1 10 Nm 1 0 m kgf 7...

Page 68: ...0 7 m kgf 5 1 ft lbf Rear wheel sensor bolt for ABS models M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear wheel sensor lead holder bolt for ABS models M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Hydraulic unit assembly unio...

Page 69: ...r ring nut 1 First tighten the lower ring nut to approximately 52 Nm 5 2 m kgf 37 ft lbf with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 18 Nm 1 8 m kg...

Page 70: ...ilter cartridge union bolt Crankcase stud bolts Starter clutch idle gear 1 shaft Starter clutch idle gear 1 Starter clutch gear inner and outer surfaces Starter clutch and metal to metal moving parts...

Page 71: ...TION POINTS AND LUBRICANT TYPES 2 28 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankcase breather pipe Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lub...

Page 72: ...ivoting point and metal to metal moving parts Footrest assembly pivoting point Throttle grip tube guide inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Bra...

Page 73: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART...

Page 75: ...strainer 2 Oil pump assembly 3 Oil delivery pipe 2 4 Relief valve assembly 5 Drive axle 6 Oil filter cartridge 7 Main axle 8 Main gallery 9 Crankshaft 10 Clutch cover 11 Valve stem end intake side 12...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil delivery pipe 2 3 Relief valve assembly...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Camshaft 2 Crankshaft...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil drain bolt 2 Crankshaft...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Drive axle 2 Oil delivery pipe 1 3 Main axle 4 Oil delivery pipe 2 5 Oil pump assembly 6 Oil strainer...

Page 84: ...CABLE ROUTING except for ABS models 2 41 EAS1XC1003 CABLE ROUTING except for ABS models Handlebar top and front view 1 2 3 4 5 6 6 A B C D G F F 5 G E 2 3 2 3 4 7 8 9 1 H I J K L 10 A D 5 6 M N O...

Page 85: ...witch lead with the plastic band at the bend in the handlebar E Fasten the left handlebar switch lead with the plastic band Align the plastic band with the locknut F Point the end of the plastic band...

Page 86: ...CABLE ROUTING except for ABS models 2 43 Headlight 3 2 2 1 A D B 1 4 5 6 7 7 8 8 9 9 10 11 C 12 12 12 13...

Page 87: ...assembly lead 11 Right handlebar switch lead 12 Wire harness 13 Left handlebar switch lead A Fasten the headlight lead and intake air temperature sensor sub wire harness with the holder Be sure to pos...

Page 88: ...E ROUTING except for ABS models 2 45 Steering head cable right side view G 4 5 H H 6 I J K L 7 M 1 2 A B C D 3 E F 7 U V W 9 X Y Z S T 1 5 AE AD AJ AA AF AB AC 14 P O N AG 6 AH AI R 10 10 8 Q 13 12 1...

Page 89: ...S Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the clutch cable and wire harness with the band making sure to point the end of the band d...

Page 90: ...CABLE ROUTING except for ABS models 2 47 Clutch cable right side view 3 3 4 3 3 H K I L A B C D E G F J J 1 2 5 6 7 8 5 5 10 10 11 11 9 3 4...

Page 91: ...O2 sensor lead with the plastic band Face the buckle of the plastic band upward with the end pointing downward F Insert the projection on the wire harness holder into the hole in the battery box G Ins...

Page 92: ...CABLE ROUTING except for ABS models 2 49 Frame inner side view A 1 2 B 3 4 5 C D E 6 F G H I J 7 8 9 10 K 11...

Page 93: ...the speed sensor D To the starter relay E Route the starter motor lead to the front of the frame cross member F Route the starter motor lead and rear brake light switch lead under the engine bracket...

Page 94: ...CABLE ROUTING except for ABS models 2 51 Rear brake hose right side view C G H E F C D A B 1 1 2 3 3 3 3 I J K L...

Page 95: ...ier regulator bracket D Fasten the brake fluid reservoir hose at the white paint mark E Route the brake fluid reservoir hose to the outside of the engine bracket rear lower side F Point the ends of th...

Page 96: ...CABLE ROUTING except for ABS models 2 53 Front brake hose front and left side view 2 A 1 1 B D 1 1 3 3 3 3 3 C...

Page 97: ...t brake hose through the cable guide B 20 40 C Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder D Fasten the front brak...

Page 98: ...CABLE ROUTING except for ABS models 2 55 Steering head left side view A B C 1 2 5 6 7 8 9 10 D F G 11 12 K J I H L M N 3 4 E...

Page 99: ...side with the plastic band Be sure to position the smaller coupler above the larger coupler F After connecting the immobilizer unit coupler insert the projection on the coupler into the hole in the f...

Page 100: ...CABLE ROUTING except for ABS models 2 57 Spark plug lead B A 2 2 1 1 C F 3 4 5 6 7 8 10 D E 9...

Page 101: ...inder spark plug lead with the holder B Fasten the fuel return hose with the holder C Fasten the hose protector of the fuel tank breather hose with the hose holder Make sure that the fuel tank breathe...

Page 102: ...UTING except for ABS models 2 59 Electrical components tray left side view 4 6 6 8 7 14 15 P S P Q 1 2 3 4 4 5 6 7 12 3 1 1 3 3 4 2 3 20 20 A C D E F G H I J K L M N O U W X V B B R 8 9 10 11 13 16 17...

Page 103: ...rt the projection on the coupler cover into the hole in the frame L Fasten the oil level switch lead and sidestand switch lead with the holder Position the holder between the sidestand switch coupler...

Page 104: ...CABLE ROUTING except for ABS models 2 61 Rectifier regulator rear view 1 2 3 4 5 6 8 9 10 10 11 A B C 14 D 12 F G H 15 16 I 7 E 13...

Page 105: ...ery A Insert the projection the stator motor lead holder into the hole in the engine bracket rear lower bracket B Insert the projection on the wire harness holder into the hole in the battery box C In...

Page 106: ...CABLE ROUTING except for ABS models 2 63 Rear fender top and left view 1 2 3 4 4 A B 6 2 5 5 1 1 1 7 8 C C C D E H F G 3 9 10 11...

Page 107: ...ute the tail sub wire harness through the guides and then secure the lead by bending the guides around the lead B Align the white tape on the tail sub wire harness with the guide C Install each couple...

Page 108: ...CABLE ROUTING except for ABS models 2 65 Fuel tank 5 K 1 M H 8 8 R 10 10 3 7 7 7 9 N O P Q I H J J 2 3 4 5 6 D E F F G L L A B C 1 2 11...

Page 109: ...n or more I Install the fuel return hose completely onto the hose fitting of the pressure regulator making sure that the yellow paint mark on the hose is facing outward J Align the ends of the hose cl...

Page 110: ...CABLE ROUTING except for ABS models 2 67 Fuel tank breather hose left and rear view D 1 A 1 1 2 2 B B 3 3 C...

Page 111: ...overflow hose from rollover valve A Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box B 2 8 mm 0 08 0 31 in C Install the fuel tank breather hose hose joint...

Page 112: ...CABLE ROUTING except for ABS models 2 69 Fuel tank breather hose right side view 1 2 3 A B...

Page 113: ...Intake air pressure hose 2 Intake air pressure sensor 3 Fuel tank breather hose hose joint to rollover valve A Point the ends of the hose clamp to the right B Install the intake air pressure hose wit...

Page 114: ...CABLE ROUTING except for ABS models 2 71 Intake air pressure sensor hose top view 1 B C 2 A...

Page 115: ...pressure sensor hose 2 Hose fitting A Point the ends of the hose clamp to the right B Install the intake air pressure sensor hose completely onto the hose fitting making sure that the yellow paint ma...

Page 116: ...CABLE ROUTING except for ABS models 2 73 Crankcase breather hose left side view H 1 A A B 1 C 2 D F G I 3 E...

Page 117: ...ioner D Point the ends of the hose clamp rearward E Align the hose clamp with the yellow paint mark on the crankcase breather hose F Install the crankcase breather hose completely onto the hose joint...

Page 118: ...CABLE ROUTING for ABS models 2 75 EAS1XC1004 CABLE ROUTING for ABS models Handlebar top and front view 1 2 3 4 5 6 6 A B C D G F F 5 G E 2 3 2 3 4 7 8 9 1 H I J K L 10 A D 5 6 M N O...

Page 119: ...end in the handlebar E Fasten the left handlebar switch lead with the plastic band Align the plastic band with the locknut F Point the end of the plastic band downward G Face the buckle of the plastic...

Page 120: ...CABLE ROUTING for ABS models 2 77 Headlight 3 2 2 1 A D B 1 4 5 6 7 7 8 8 9 9 10 11 C 12 12 12 13...

Page 121: ...Clutch cable 10 Meter assembly lead 11 Right handlebar switch lead 12 Wire harness 13 Left handlebar switch lead A Fasten the headlight lead and intake air temperature sensor sub wire harness with th...

Page 122: ...E ROUTING for ABS models 2 79 Steering head cable right side view G 4 5 6 H H 7 I J K L 8 M 1 2 A B C D 3 E F 8 U V W 10 X Y Z S T 1 6 AF AE AK AB AA AG AC AD 15 P O N AH 7 AI AJ R 11 11 9 Q 14 13 1 6...

Page 123: ...park plug lead is not pinched between the rear cylinder head and the rear right cylinder head cover T Secure the plastic band by inserting the projection on the band into the hole in the frame and the...

Page 124: ...CABLE ROUTING for ABS models 2 81 Clutch cable right side view A B C D E G F 1 2 6 7 8 5 9 3 4 12 J I H 11 10 3 3 4 3 3 K N L O M M 5 5 13 13 14 14...

Page 125: ...to route the rear wheel sensor lead to the outside of the frame G Fasten the brake fluid reservoir hose rear brake light switch lead and O2 sensor lead with the plastic band Face the buckle of the pla...

Page 126: ...CABLE ROUTING for ABS models 2 83 Frame inner side view A 1 2 B 3 4 5 C D 6 E F G H I 7 8 9 10 J 11 13 12...

Page 127: ...er cover the couplers with the coupler cover C To the starter relay D Route the starter motor lead to the front of the frame cross member E Route the starter motor lead and rear brake light switch lea...

Page 128: ...CABLE ROUTING for ABS models 2 85 Rear brake hose right side view 1 2 4 4 5 4 5 4 5 I 1 2 B 3 G A H F D E C...

Page 129: ...eservoir hose at the white paint mark with the holder C To the rear wheel sensor coupler D 85 95 mm 3 35 3 74 in E 75 85 mm 2 95 3 35 in F To the rear wheel sensor coupler G Route the rear wheel senso...

Page 130: ...CABLE ROUTING for ABS models 2 87 Hydraulic unit inner and left side view 1 2 3 4 A B A B 1 2 3 4 5 5 6...

Page 131: ...to hydraulic unit 5 Brake hose hydraulic unit to rear brake caliper 6 Rubber cover A Route the brake hose front brake master cylinder to hydraulic unit and brake hose hydraulic unit to front brake ca...

Page 132: ...CABLE ROUTING for ABS models 2 89 Front brake hose front and right side view 1 A B 1 1 1 2 C D...

Page 133: ...embly front brake master cylinder to hydraulic unit through the cable guide B Route the brake pipe hose assembly front brake master cylinder to hydraulic unit between the front fork and the pipe secti...

Page 134: ...CABLE ROUTING for ABS models 2 91 Front brake hose left side view 4 4 5 1 2 3 3 6 7 7 A A B E F E E 7 5 5 G H C C D...

Page 135: ...in the brake hose bracket and then fasten the brake hose hydraulic unit to front brake caliper and brake hose front brake master cylinder to hydraulic unit with the holder C 85 95 mm 3 35 3 74 in D 75...

Page 136: ...CABLE ROUTING for ABS models 2 93 Steering head left side view A B C 1 2 5 6 7 8 9 10 D E F G 11 13 12 K J I H L M N O P 3 4...

Page 137: ...ront wheel sensor lead to the outside of the engine bracket front upper side G Route the fuel pump lead to the outside of the main switch leads and immobilizer unit lead and then fasten the fuel pump...

Page 138: ...CABLE ROUTING for ABS models 2 95 Spark plug lead 3 3 4 4 5 6 7 8 9 10 11 12 C D A B 1 1 2 2...

Page 139: ...cylinder head cover 10 Wire harness 11 Crankcase breather hose 12 Hose holder A Fasten the front cylinder spark plug lead with the holder B Fasten the fuel return hose with the holder C Fasten the hos...

Page 140: ...TING for ABS models 2 97 Electrical components tray left side view 4 8 8 9 16 17 Q T Q R 1 2 3 4 4 7 14 3 1 1 3 3 4 2 3 A C F E G H I J K L M N O P V X Y W B B S 8 9 11 15 18 19 U 5 D 6 10 12 13 10 5...

Page 141: ...necting the sidestand switch coupler insert the projection on the coupler cover into the hole in the frame M Fasten the oil level switch lead and sidestand switch lead with the holder Position the hol...

Page 142: ...CABLE ROUTING for ABS models 2 99 Rectifier regulator rear view 1 2 3 4 5 6 9 10 11 11 A B C 14 D 12 F G H 15 17 16 I 7 E 13 8...

Page 143: ...nd 17 Battery A Insert the projection the stator motor lead holder into the hole in the engine bracket rear lower bracket B Insert the projection on the wire harness holder into the hole in the batter...

Page 144: ...CABLE ROUTING for ABS models 2 101 Rear fender top and left view 1 2 3 4 4 A B 6 2 5 5 1 1 1 7 8 C C C D E H F G 3 9 10 11...

Page 145: ...the tail sub wire harness through the guides and then secure the lead by bending the guides around the lead B Align the white tape on the tail sub wire harness with the guide C Install each coupler s...

Page 146: ...CABLE ROUTING for ABS models 2 103 Fuel tank 5 K 1 M H 8 8 R 10 3 7 7 7 9 N O P Q I H J J 2 3 4 5 6 D E F F G L 10 L A B C 1 2 11...

Page 147: ...r more I Install the fuel return hose completely onto the hose fitting of the pressure regulator making sure that the yellow paint mark on the hose is facing outward J Align the ends of the hose clamp...

Page 148: ...CABLE ROUTING for ABS models 2 105 Fuel tank breather hose left and rear view D 1 A 1 1 2 2 B B 3 3 C...

Page 149: ...rflow hose from rollover valve A Route the fuel tank breather hose hose joint to rollover valve to the left of the battery box B 2 8 mm 0 08 0 31 in C Install the fuel tank breather hose hose joint to...

Page 150: ...CABLE ROUTING for ABS models 2 107 Fuel tank breather hose right side view 1 2 3 A B...

Page 151: ...take air pressure hose 2 Intake air pressure sensor 3 Fuel tank breather hose hose joint to rollover valve A Point the ends of the hose clamp to the right B Install the intake air pressure hose with i...

Page 152: ...CABLE ROUTING for ABS models 2 109 Intake air pressure sensor hose top view 1 B C 2 A...

Page 153: ...essure sensor hose 2 Hose fitting A Point the ends of the hose clamp to the right B Install the intake air pressure sensor hose completely onto the hose fitting making sure that the yellow paint mark...

Page 154: ...CABLE ROUTING for ABS models 2 111 Crankcase breather hose left side view H 1 A A B 1 C 2 D F G I 3 E...

Page 155: ...er D Point the ends of the hose clamp rearward E Align the hose clamp with the yellow paint mark on the crankcase breather hose F Install the crankcase breather hose completely onto the hose joint mak...

Page 156: ...CABLE ROUTING for ABS models 2 113...

Page 157: ...E FRONT BRAKE HOSE 3 14 CHECKING THE REAR BRAKE HOSES 3 15 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 15 CHECKING THE WHEEL BEARINGS 3 17 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 3 17 CHECKING TH...

Page 158: ...KING THE THROTTLE GRIP OPERATION 3 26 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE 3 27 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 27 ADJUSTING THE HEADLIGHT BEAM 3 27 REPLACING THE HEADLIGHT BULB...

Page 159: ......

Page 160: ...he annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance inter...

Page 161: ...ened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease...

Page 162: ...maging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level...

Page 163: ...vent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is me...

Page 164: ...1 5 Disconnect Spark plug caps Refer to ENGINE REMOVAL on page 5 3 6 Remove Spark plugs Refer to CAMSHAFTS on page 5 16 7 Remove Damper cover Generator cover damper Timing mark accessing screw Cranks...

Page 165: ...learance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure the valve clearance with a thic...

Page 166: ...properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 6 1 Air duct Refer to BELT DRIVE on page 4 94 Air filter case Refer t...

Page 167: ...o adjust its vacuum pressure c If the vacuum pressure of the throttle body with the lower pressure is out of specification adjust it to specification first and then syn chronize the throttle bodies TI...

Page 168: ...nd exhaust bolt 11 Muffler bracket and muffler bolts 12 EAS1XC1027 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume To adjust...

Page 169: ...Check the clutch system Refer to CLUTCH on page 5 48 WARNING EWA1TP1010 Before checking the clutch operation check the brake system and make sure that the brake is operating at all times during the c...

Page 170: ...brakes are operating fully EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake flui...

Page 171: ...he brake 2 Check Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 47 EAS1XC1029 BLEEDING THE HYDRAULIC BRAKE SYSTEM except for...

Page 172: ...3 11 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation 3 Install Brake fluid reservoir cover EAS1XC1030 BLEEDING THE HYDRAULIC BRAKE SYSTEM for ABS models WARNING EW...

Page 173: ...ntil all of the air bub bles have disappeared from the brake fluid in the plastic hose j Check the operation of the hydraulic unit Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 67 NOTICE ECA1XC100...

Page 174: ...e Tighten the holder bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 47 EAS21670 CHECKI...

Page 175: ...n deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are cente...

Page 176: ...1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 13 and CHECKING THE REAR WHEEL on page 4 25 EAS1TP1021 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 1 Check Swingarm pivot shaft beari...

Page 177: ...curely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the sidestand or on a suit able stand so that the rear wheel is elevated 2 Rotate the rear wheel sever...

Page 178: ...ING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bo...

Page 179: ...he ring nut slots c 5 Install Upper bracket Refer to STEERING HEAD on page 4 85 EAS1TP1023 LUBRICATING THE STEERING BEARINGS Lubricate the steering bearings EAS1TP1024 CHECKING THE CHASSIS FASTENERS M...

Page 180: ...CH Refer to ELECTRICAL COMPONENTS on page 7 147 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it f...

Page 181: ...STING THE REAR SHOCK ABSORBER ASSEMBLIES for models equipped with gas cylinders The following procedure applies to both of the rear shock absorber assemblies WARNING EWA1XC1009 Securely support the ve...

Page 182: ...pes or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils la beled ENERGY CONSERVING II or high er Do...

Page 183: ...e the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt alo...

Page 184: ...cover bracket Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 3 EAS1TP1030 CHECKING THE BRAKE LIGHT SWITCH 1 Check Front brake light switch operation Rear brake light switch operation Whe...

Page 185: ...ubricate or replace the defective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Rep...

Page 186: ...and that all lights come on Refer to INSTRUMENT AND CONTROL FUNCTIONS in Owner s manual Faulty Refer to CHECKING THE SWITCHES on page 7 151 and CHECK ING THE BULBS AND BULB SOCKETS on page 7 154 EAS2...

Page 187: ...90 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the he...

Page 188: ...PERIODIC MAINTENANCE 3 29 3 Remove Auxiliary light bulb 1 4 Install Auxiliary light bulb Auxiliary light socket 5 Install Headlight lens unit Refer to GENERAL CHASSIS on page 4 1 1 1 New...

Page 189: ...HE REAR WHEEL DRIVE HUB 4 26 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 26 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR for ABS models 4 26 ASSEMBLING THE REAR WHEEL 4 27 ADJUSTING THE RE...

Page 190: ...ESTS 4 65 CHECKING THE ABS WARNING LIGHT 4 68 HANDLEBAR 4 69 REMOVING THE HANDLEBAR 4 71 CHECKING THE HANDLEBAR 4 71 INSTALLING THE HANDLEBAR 4 71 FRONT FORK 4 74 REMOVING THE FRONT FORK LEGS 4 78 DIS...

Page 191: ...BELT DRIVE 4 92 REMOVING THE DRIVE BELT AND DRIVE PULLEY 4 93 CHECKING THE DRIVE BELT 4 93 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 93...

Page 192: ...eat 1 5 Battery cover holder 1 6 Battery cover 1 7 Brake fluid reservoir cover 1 8 Brake fluid reservoir 1 9 Right side cover 1 For installation reverse the removal proce dure LT 2 3 Nm 0 23 m kgf 1 7...

Page 193: ...eat 1 TIP Insert the projection a on the rear of the seat into the seat holder b as shown While pushing the front of the seat down so that there is no space between the rubber dampers c and the frame...

Page 194: ...ry band 2 5 ECU bracket 1 6 Negative battery lead 1 Disconnect 7 Positive battery lead 1 Disconnect 8 Battery 1 9 Tool box band 1 10 Tool box 1 11 Relay unit 1 12 Turn signal hazard relay 1 13 Head li...

Page 195: ...battery lead starter relay 1 Disconnect 21 Starter relay 1 For installation reverse the removal proce dure Removing the battery and relays Order Job Parts to remove Q ty Remarks 1 5 Nm 0 15 m kgf 1 1...

Page 196: ...GENERAL CHASSIS 4 5 EAS1TP1065 INSTALLING THE TOOL BOX 1 Install Tool box 1 TIP Install the tool box with the INSIDE mark a facing inward 1 a...

Page 197: ...Remarks 1 Air filter case cover 1 2 Air filter element 1 3 Air filter case 1 4 Crankcase breather hose 1 Disconnect For installation reverse the removal proce dure New New 2 0 Nm 0 20 m kgf 1 4 ft Ib...

Page 198: ...light coupler 1 Disconnect Refer to CABLE ROUTING except for ABS models on page 2 41 and CABLE ROUT ING for ABS models on page 2 75 12 Rear right turn signal light coupler 1 Disconnect Refer to CABLE...

Page 199: ...rear fender Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft...

Page 200: ...1 Disconnect 3 Auxiliary light coupler 1 Disconnect 4 Intake air temperature sensor coupler 1 5 Headlight body 1 For installation reverse the removal proce dure 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7...

Page 201: ...the front wheel is elevated 1 Front brake caliper 1 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle cap 1 Except for AUS 4 Front wheel axle 1 5 Front wheel 1 6 Collar 2 7 Front brake disc 1...

Page 202: ...d holder 1 2 Front brake caliper 1 3 Front wheel sensor 1 4 Front wheel axle pinch bolt 2 Loosen 5 Front wheel axle cap 1 6 Front wheel axle 1 7 Front wheel 1 8 Collar 2 9 Front brake disc 1 For insta...

Page 203: ...heel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 For ABS models 2 Oil seal 2 3 Wheel bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure 4 3 2 2 3 1 New New Ne...

Page 204: ...Do not apply the brake lever when remov ing the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the outer tube for ABS models 3 El...

Page 205: ...ents with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If f...

Page 206: ...or rotor EAS21960 ASSEMBLING THE FRONT WHEEL NOTICE ECA1XC1011 For ABS models Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off imm...

Page 207: ...static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitabl...

Page 208: ...L FRONT BRAKE DISC 1 Install Front brake disc TIP Apply locking agent LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern Install the brak...

Page 209: ...t wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by...

Page 210: ...er to GENERAL CHASSIS on page 4 1 1 Rear brake caliper 1 2 Drive belt upper guard 1 3 Drive belt adjusting bolt locknut 2 Loosen 4 Drive belt adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1...

Page 211: ...removal proce dure Removing the rear wheel except for ABS models Order Job Parts to remove Q ty Remarks LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R...

Page 212: ...ar wheel sensor lead holder 1 3 Rear wheel sensor 1 4 Drive belt upper guard 1 5 Drive belt adjusting bolt locknut 2 Loosen 6 Drive belt adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Re...

Page 213: ...ure Removing the rear wheel for ABS models Order Job Parts to remove Q ty Remarks LS S S 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft...

Page 214: ...r wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 8 Bearing 1 9 Collar 1 10 Bearing 1 11 Collar 1 12 Rear wheel drive hub damper 6 13 Rear wheel 1 For installation reverse...

Page 215: ...EAR WHEEL 4 24 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Bearing 1 2 Oil seal 1 3 Bearing 1 4 Spacer 1 For assembly reverse the disassembly pro cedure LS New New New 4 1 3...

Page 216: ...depress the brake pedal when re moving the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket for ABS...

Page 217: ...TOR for ABS models NOTICE ECA1XC1012 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cann...

Page 218: ...spacer 5 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the bra...

Page 219: ...to ADJUSTING THE DRIVE BELT SLACK on page 3 18 8 Tighten Rear wheel axle nut 9 Install for ABS models Rear wheel sensor NOTICE ECA1XC1023 Make sure there are no foreign materials in the rear wheel se...

Page 220: ...t TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is install...

Page 221: ...marks 1 Front brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 2 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal...

Page 222: ...brake caliper retaining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 2 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal proce dure 6 6...

Page 223: ...1 3 Brake master cylinder reservoir diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake light switch 1 8 F...

Page 224: ...Removing the front brake master cylinder Order Job Parts to remove Q ty Remarks 7 6 1 2 3 4 5 8 9 10 11 12 New S 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 Nm 0 1 m kgf 0 7 ft Ibf T R 1 Nm 0 1 m kgf 0 7 ft I...

Page 225: ...34 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF...

Page 226: ...to BLEEDING THE HYDRAULIC BRAKE SYSTEM except for ABS models on page 3 12 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Front brake hose 1 4 Front brake caliper bracket bolt 2 5 Front brake...

Page 227: ...r ABS models on page 3 13 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Brake pipe hose assembly hydraulic unit to front brake caliper 1 4 Front brake caliper bracket bolt 2 5 Front wheel se...

Page 228: ...rake pad spring 1 5 Brake pad support 2 6 Brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 11 Bush 1 For ABS models Fo...

Page 229: ...to hy draulic unit 1 Disconnect 6 Brake pipe hose assembly holder rear side 1 7 Brake pipe hose assembly holder front side 1 8 Brake pipe hose assembly hydraulic unit to front brake caliper 1 9 Brake...

Page 230: ...10 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...

Page 231: ...pad shims brake pad supports and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed scre...

Page 232: ...ABS models TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons 1 Brake caliper pist...

Page 233: ...o swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brak...

Page 234: ...dels on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer...

Page 235: ...ake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install Brake hose gaskets Front brake hose 1 Front brake hose union bolt 2 WARNIN...

Page 236: ...eling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM except for ABS models on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 EAS1XC1055 INSTALLIN...

Page 237: ...Install Brake hose gaskets Brake hose hydraulic unit to front brake cali per Brake hose front brake master cylinder to hydraulic unit Front brake hose union bolts WARNING EWA1XC1013 Proper brake hose...

Page 238: ...to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Rear brake pad shim 2 5 Rear brake pad spring 2 For installation reverse the removal proce dur...

Page 239: ...rvoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose ho...

Page 240: ...removal proce dure Removing the rear brake master cylinder except for ABS models Order Job Parts to remove Q ty Remarks New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 23 N...

Page 241: ...voir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose wheel sensor lead holder 1 8 Rear w...

Page 242: ...witch 1 For installation reverse the removal proce dure Removing the rear brake master cylinder for ABS models Order Job Parts to remove Q ty Remarks New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 8 Nm 0...

Page 243: ...er Job Parts to remove Q ty Remarks 1 Rear brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Brake hose joint 1 4 Bush 1 5 Brake master cylinder body 1 For assembly reverse the disassembly...

Page 244: ...for ABS models on page 3 12 and BLEEDING THE HY DRAULIC BRAKE SYSTEM for ABS mod els on page 3 13 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper retainin...

Page 245: ...rake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper bracket 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad spring 2 For assembly reve...

Page 246: ...Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 39 4...

Page 247: ...ified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC...

Page 248: ...E REAR BRAKE CALIPER WARNING EWA1TP1007 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponen...

Page 249: ...of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system...

Page 250: ...and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Install Brake hose joint Brake master cylinder kit Rear brake master cylinder joint TIP The rear brake...

Page 251: ...he brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Theref...

Page 252: ...age 4 94 Drive pulley housing Refer to ENGINE REMOVAL on page 5 3 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Brake hose rear brake master cylinder to hy draulic u...

Page 253: ...installation reverse the removal proce dure Removing the hydraulic unit assembly and brackets Order Job Parts to remove Q ty Remarks New New New 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf...

Page 254: ...E SYS TEM for ABS models on page 4 61 1 Hydraulic unit assembly 1 2 Hydraulic unit assembly upper bracket 1 3 Hydraulic unit assembly lower bracket 1 4 Rubber cover 1 5 Seal 1 For installation reverse...

Page 255: ...em to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupl...

Page 256: ...the specified torque starting with the bolt 1 5 Install Brake hose hydraulic unit to front brake cali per 1 Brake hose front brake master cylinder to hydraulic unit 2 Brake hose hydraulic unit to rear...

Page 257: ...reful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted...

Page 258: ...the wheels are not rotating 1 Place the vehicle on a suitable stand 2 Turn the main switch to OFF 3 Remove Left side cover Rider seat ECU bracket Battery cover Refer to GENERAL CHASSIS on page 4 1 4 C...

Page 259: ...c unit assembly 10 If the operation of the hydraulic unit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no dang...

Page 260: ...been met Off The brake lever and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsati...

Page 261: ...assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch...

Page 262: ...lebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Clutch switch coupler 1 Disconnect 9 Left handlebar switch 1 10 Handlebar grip 1 11 Clutch cable 1 Disconnect 12 Clutch lever 1 13 Clut...

Page 263: ...llation reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks LT LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 264: ...bar 1 Upper handlebar holders 2 NOTICE ECA1TP1010 First tighten the bolts on the upper side of the upper handlebar holder and then on the lower side Turn the handlebar all the way to the left and righ...

Page 265: ...ndlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be less than 3 mm 0 12 in of...

Page 266: ...mark a on the handle bar First tighten the upper bolt then the lower bolt 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 10 12 Adjust Throttle grip free play...

Page 267: ...light pinch bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 9 Air temperature sensor bracket 1 Left side only 10 Air temperature sensor 1 Left side only 11 Front turn signal ligh...

Page 268: ...gnal light pinch bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 9 Air temperature sensor bracket 1 Left side only 10 Air temperature sensor 1 Left side only 11 Front turn signal...

Page 269: ...fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 11 Damper rod 1 12 Damper rod ring 1 13 Rebound...

Page 270: ...low stopper 1 20 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks LT LS LS LS New 7 New 8 New 15 16 1 New 17 20 New...

Page 271: ...hile drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Front fork damper rod bolt 1 Copper washer TIP While...

Page 272: ...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 Mak...

Page 273: ...p TIP 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 f...

Page 274: ...with the outer tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and d...

Page 275: ...coupler into the slot a in the front turn signal light 2 Install Front fork leg 1 Temporarily tighten the lower bracket pinch bolts TIP Make sure the inner tube end is flush with the top of the upper...

Page 276: ...light bracket 1 2 Front brake hose holder 1 Except for ABS models 3 Front brake hose wheel sensor lead holder 1 For ABS models 4 Steering stem nut 1 5 Washer 1 6 Upper bracket 1 7 Lock washer 1 8 Uppe...

Page 277: ...outer race 2 19 Lower bracket cap 1 For installation reverse the removal proce dure Removing the upper bracket and lower bracket Order Job Parts to remove Q ty Remarks 11 10 9 8 7 12 13 18 14 18 15 17...

Page 278: ...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 NOTICE ECA14270...

Page 279: ...ket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 76 TIP Temporarily tighten the upper and lower bracket pinch bolts 6...

Page 280: ...Drive belt lower guard 1 2 Rear brake hose guide 1 3 Rear shock absorber assembly 2 4 Pivot shaft cover 2 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Collar 2 9 Dust seal 2 10 Spacer 2 11 Dust...

Page 281: ...oce dure Removing the swingarm and rear shock absorber assemblies Order Job Parts to remove Q ty Remarks LS LS LS New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kg...

Page 282: ...p or down e If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings collars and dust seals EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Re...

Page 283: ...rotection to prevent eye damage from released gas or metal chips EAS1XC1039 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber ass...

Page 284: ...ped with gas cylinders 5 Tighten Rear shock absorber assembly upper bolt 6 Tighten Rear shock absorber assembly lower nut 7 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 18...

Page 285: ...89 1 Air duct 1 2 Drive pulley cover 1 3 Drive belt 1 4 Speed sensor coupler 1 Disconnect Except for ABS models 5 Speed sensor 1 Except for ABS models 6 Speed sensor bracket 1 Except for ABS models 7...

Page 286: ...rt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check Drive belt NOTICE ECA1TP1030 To protect the drive belt...

Page 287: ...s a in the drive axle When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move 4 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 1...

Page 288: ...BELT DRIVE 4 97...

Page 289: ...HE CYLINDER HEAD COVERS 5 25 CYLINDER HEADS 5 26 REMOVING THE CYLINDER HEADS 5 27 CHECKING THE CYLINDER HEADS 5 27 INSTALLING THE CYLINDER HEADS 5 27 VALVES AND VALVE SPRINGS 5 29 REMOVING THE VALVES...

Page 290: ...THE STOPPER LEVER 5 60 INSTALLING THE SHIFT SHAFT 5 60 ELECTRIC STARTER 5 61 CHECKING THE STARTER MOTOR 5 63 ASSEMBLING THE STARTER MOTOR 5 64 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 69 CHECKING...

Page 291: ...ION 5 80 CHECKING THE SHIFT FORKS 5 83 CHECKING THE SHIFT DRUM ASSEMBLY 5 83 CHECKING THE TRANSMISSION 5 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEM...

Page 292: ...the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 0 kgf cm 14 5 psi c If the compression pressu...

Page 293: ...ENGINE INSPECTION 5 2 10 Install Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 3...

Page 294: ...bracket 1 13 Exhaust pipe protector 3 1 14 Muffler protector 1 1 15 Muffler protector 2 1 16 Muffler cap 1 1 18 13 2 16 3 14 15 17 5 7 8 9 6 6 10 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT...

Page 295: ...6 6 10 11 12 4 LT New New New New LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT LT 5 LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m k...

Page 296: ...haust pipe protector 2 bracket band so that its section to crimp is positioned at the location a shown in the illustration TIP Be sure to place the exhaust pipe protector 2 bracket band over the exhau...

Page 297: ...wn 2 Install Clamp 1 to the muffler assembly TIP Fit the projection a on the clamp into the slot b shown in the illustration Temporarily tighten the clamp bolt 2 3 Install Muffler assembly Muffler bra...

Page 298: ...8 Rear cylinder left cover bracket 1 9 Rear cylinder right cover bracket 1 10 Ground lead 1 Disconnect 11 Drive pulley housing 1 12 Neutral switch sub wire harness 1 13 Damper 1 14 Dowel pin 2 15 Side...

Page 299: ...ove Q ty Remarks LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R...

Page 300: ...26 The shift rod locknut shift pedal side has left hand threads b Turn the shift rod 2 in direction a or b to obtain the correct shift rod length TIP Make sure that the engaged thread length on both e...

Page 301: ...anifold assem bly Refer to THROTTLE BODIES on page 6 6 1 Starter motor lead 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Oil level switch coupler 1 Di...

Page 302: ...NE REMOVAL 5 11 EAS1TP1070 INSTALLING THE HORN 1 Install Horn 1 TIP Make sure that the horn bracket 2 contacts the portion a of the stay on the frame T R Horn bracket bolt 30 Nm 3 0 m kgf 22 ft lbf 1...

Page 303: ...e 2 7 Engine bracket front lower side 1 8 Engine mounting bolt rear lower side 1 9 Engine bracket bolt rear lower side 2 10 Engine bracket rear lower side 1 11 Engine bracket nut front upper side 2 12...

Page 304: ...or installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks LT LT LT LS 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 88 Nm 8 8 m kgf 64 ft...

Page 305: ...5 Engine mounting nut rear upper side 16 Engine mounting nut front upper side 17 Engine mounting nut rear lower side 18 Engine mounting nut front lower side 19 TIP Lubricate the engine mounting bolt f...

Page 306: ...t rear lower side 18 Engine mounting nut front lower side 19 T R Engine mounting nut rear upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mounting nut front upper side 88 Nm 8 8 m kgf 64 ft lbf Engine mou...

Page 307: ...Intake manifold assembly Refer to THROTTLE BODIES on page 6 6 1 Tappet cover 4 2 O ring 4 3 Fuel filter bracket 1 4 Front cylinder side cover 1 5 Front cylinder side cover gasket 1 6 Rear cylinder sid...

Page 308: ...ain tensioner gasket 2 6 Camshaft bolt 2 7 Camshaft sprocket 2 8 Camshaft retainer 2 9 Front cylinder camshaft 1 10 Rear cylinder camshaft 1 11 Intake rocker arm shaft 2 12 Intake rocker arm 2 13 Exha...

Page 309: ...T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m...

Page 310: ...I mark c on the camshaft sprocket with the arrow mark d on the front cylinder head 2 Remove Front cylinder timing chain tensioner 1 3 Remove Front cylinder camshaft sprocket TIP While holding the cams...

Page 311: ...he camshaft sprocket with the arrow mark d on the rear cylinder head 7 Remove Rear cylinder timing chain tensioner Rear cylinder camshaft sprocket Camshaft retainer Rear cylinder camshaft Intake rocke...

Page 312: ...ion excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of sp...

Page 313: ...er gasket 5 Timing chain tensioner rod 6 Damage wear Replace the defective part s EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camsha...

Page 314: ...mark c on the camshaft sprocket with the arrow mark d on the front cylinder head When installing the front cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the exhau...

Page 315: ...the crankshaft when installing the camshaft s to avoid damage or improper valve timing TIP To position the rear cylinder piston at TDC on the compression stroke align the I mark c on the camshaft spro...

Page 316: ...STING THE VALVE CLEAR ANCE on page 3 4 EAS1TP1053 INSTALLING THE CYLINDER HEAD COVERS 1 Install Rear cylinder side cover Fuel filter bracket Tappet covers 2 Install Front cylinder side cover Tappet co...

Page 317: ...pin 4 8 Cylinder head gasket 2 9 Timing chain guide exhaust side 1 10 Timing chain guide intake side 1 For installation reverse the removal proce dure 1st 15 Nm 1 5 m kgf 11 ft Ibf Final 65 Nm 6 5 m...

Page 318: ...amag ing or scratching 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 st...

Page 319: ...cylinder head nuts in the proper tightening sequence as shown and torque them in three stages T R Cylinder head nut 1st 15 Nm 1 5 m kgf 11 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf Final 65 Nm 6 5 m kgf 47...

Page 320: ...ty Remarks The following procedure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 26 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust val...

Page 321: ...cotters TIP 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...

Page 322: ...stem to valve guide clearance TIP 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...

Page 323: ...s from 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 blue layout fluid b o...

Page 324: ...ping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping p...

Page 325: ...3 Lubricate Valve stem end with the recommended lubricant Free length intake 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Free length exhaust 42 43 mm 1 67 in Limit 40 31 mm 1 59 in Installed compression s...

Page 326: ...tall the 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...

Page 327: ...ts to remove Q ty Remarks Cylinder heads Refer to CYLINDER HEADS on page 5 26 1 Front cylinder 1 2 Rear cylinder 1 3 Front cylinder gasket 1 4 Rear cylinder gasket 1 5 Dowel pin 4 6 Circlip 4 7 Piston...

Page 328: ...ap 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...

Page 329: ...ation Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring...

Page 330: ...fication 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...

Page 331: ...ston fac es towards the front side of the cylinder Before installing the circlips cover the crank case opening with a clean rag to prevent the clips from falling into the crankcase Install the circlip...

Page 332: ...AND PISTONS 5 41 6 Install Cylinder 1 TIP 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 cha...

Page 333: ...5 3 1 Rectifier regulator coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Damper cover 1 4 Generator cover damper 1 5 Crankshaft end accessing screw 1 6 Timing mark accessing...

Page 334: ...For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks LT LT LT 11 1 12 13 10 9 7 4 3 5 6 10 8 2 12 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m...

Page 335: ...rotor 1 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Starter clutch idle gear 2 shaft 1 6 Starter clutch idle gear 2 1 7 Starter clutch idle gear 1 shaft 1 8 Starter clutch idle gear...

Page 336: ...r clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2...

Page 337: ...NSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure...

Page 338: ...TCH 5 47 EAS1TP1054 INSTALLING THE GENERATOR COVER 1 Install TIP Temporally tighten a and b and then tighten the generator cover bolts in the order shown in the illustration T R Generator cover bolt 1...

Page 339: ...r Refer to GENERATOR AND STARTER CLUTCH on page 5 42 Rear brake master cylinder Right footrest as sembly Rear brake light switch Refer to REAR BRAKE on page 4 47 1 Circlip 1 2 Pull lever 1 3 Pull leve...

Page 340: ...ve gear 1 15 Woodruff key 1 For installation reverse the removal proce dure Removing the primary drive gear Order Job Parts to remove Q ty Remarks LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kg...

Page 341: ...r 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 6 Oil seal retainer 1 7 Oil seal 1 For installation reverse the removal proce dure...

Page 342: ...plate 1 2 Inside diameter 124 mm 4 88 in 8 Clutch plate 8 9 Friction plate 2 7 Inside diameter 124 mm 4 88 in 10 Clutch boss nut 1 11 Conical spring washer 1 12 Clutch boss 1 13 Thrust washer 1 1 14...

Page 343: ...r 2 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 8 Nm 0 8 m kgf 5 8 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R New 6 9 8 8 8 8 8 8 8 9 9...

Page 344: ...boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 3 Remove Clutch boss nut 1 Conical spring washer 2 Clutch boss 3 EAS25100 CHECKING THE FR...

Page 345: ...e Replace 3 Measure Clutch spring free height Out of specification Replace the clutch spring plate EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutc...

Page 346: ...place the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL R...

Page 347: ...s with engine oil Install the conical spring washer with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss n...

Page 348: ...1 Pull lever 2 Washer Circlip TIP Make sure that the mark a on the pull lever is facing forward When installing the pull lever push it and check that its punch mark b aligns with the mark c on the cl...

Page 349: ...her with the groove b in the spacer While holding the generator rotor 4 with the sheave holder 5 tighten the primary drive gear nut Do not allow the sheave holder to touch the projection on the genera...

Page 350: ...94 Shift arm Refer to ENGINE REMOVAL on page 5 3 Clutch cover Clutch housing Refer to CLUTCH on page 5 48 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 Shift shaf...

Page 351: ...AFT 1 Install Bearing 1 Oil seals 2 to the crankcase 2 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 TIP Lubricate the oil seal lips with lithium soap based grease Hook the ends of the...

Page 352: ...g 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0...

Page 353: ...Remarks 1 O ring 1 2 Starter motor front cover 1 3 Armature assembly 1 4 Starter motor yoke 1 5 Gasket 2 6 Starter motor rear cover 1 7 Brush set assembly 1 8 O ring 1 For assembly reverse the disasse...

Page 354: ...embly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush set assembly 5 Measure B...

Page 355: ...EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Brush set assembly 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter mot...

Page 356: ...page 5 59 1 Oil level switch 1 2 Engine oil drain bolt 1 3 Neutral switch 1 4 Timing chain guide 2 5 Timing chain 2 6 Spacer 1 7 Oil filter cartridge 1 8 Oil delivery pipe 1 1 9 Oil delivery pipe 2 1...

Page 357: ...to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft I...

Page 358: ...ate 1 1 2 Left crankcase 1 3 Dowel pin 2 4 Joint pipe 1 5 O ring 2 6 Oil baffle plate 2 1 7 Gasket 1 8 Right crankcase 1 9 Stud bolt 6 l 239 mm 9 41 in 10 Stud bolt 2 l 210 mm 8 27 in For installation...

Page 359: ...rts to remove Q ty Remarks Oil pump assembly Refer to OIL PUMP on page 5 72 Crankshaft Refer to CRANKSHAFT on page 5 75 Transmission Refer to TRANSMISSION on page 5 80 1 Bearing retainer 2 2 Oil seal...

Page 360: ...ges Obstruction Blow out with compressed air EAS1TP1056 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement...

Page 361: ...stall Crankcase bolts M10 Crankcase bolts M6 Oil baffle plate 1 bolts TIP Apply locking agent LOCTITE to the threads of the right crankcase bolts and oil baf fle plate 1 bolts Tighten the crankcase bo...

Page 362: ...CRANKCASE 5 71 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair...

Page 363: ...ief valve assembly 1 2 Oil pump assembly 1 3 Dowel pin 2 4 Oil pump housing 1 5 Dowel pin 2 6 Impeller shaft 1 7 Pin 1 8 Oil pump inner rotor 1 9 Oil pump outer rotor 1 10 Oil pump housing cover 1 11...

Page 364: ...ing 3 Spring retainer 4 Damage wear Replace the relief valve as sembly EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE...

Page 365: ...mp operation Refer to CHECKING THE OIL PUMP on page 5 73 EAS1TP1060 INSTALLING THE OIL PUMP ASSEMBLY 1 Install Oil pump assembly NOTICE ECA1TP1021 After tightening the bolts make sure the oil pump ass...

Page 366: ...kshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 1 Crankshaft 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bear...

Page 367: ...he 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 th...

Page 368: ...nce is out of specification select re placement big end bearings 4 Select Big end bearings P1 P2 TIP The numbers a on the connecting rods are used to determine the replacement big end bearing sizes P1...

Page 369: ...ended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pin TIP Align the projections a on the big end bear ings with the notches b in the connecting rods an...

Page 370: ...n and then retighten it Replace the bolt with a new one and perform the procedure again NOTICE ECA1TP1022 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until i...

Page 371: ...rder Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 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 f...

Page 372: ...2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed lock washer retainer 1 5 4th pinion gear 1 6 Collar 1 7 Toothed washer 1 8 Circlip 1 9 3rd pinion gear 1 10 Circlip 1 11 Toothed washer 1 12 5th...

Page 373: ...wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Toothed washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Circlip 1 13 T...

Page 374: ...movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift dru...

Page 375: ...s a rest on the sides of a spline b with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer in the groove a in the drive axle a...

Page 376: ...eck Transmission Rough movement Repair TIP Apply molybdenum disulfide grease to each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that...

Page 377: ...PUMP 6 4 INSTALLING THE FUEL SENDER 6 5 THROTTLE BODIES 6 6 CHECKING THE INJECTORS 6 9 INSTALLING THE INJECTORS 6 9 CHECKING THE THROTTLE BODIES 6 9 CHECKING THE INTAKE MANIFOLD JOINTS 6 9 CHECKING TH...

Page 378: ...Disconnect 6 Fuel hose fuel pump to fuel hose 1 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel sender 1 10 Fuel pump cover 1 11 Fuel pump 1 12 Fuel tank bracket 1 13 Fuel tank bracket damper 1...

Page 379: ...egulator bracket 1 4 Fuel tank breather overflow hose fuel tank to fuel hose joint 1 5 Fuel hose joint 1 6 Fuel tank breather overflow hose fuel hose joint to rollover valve 1 7 Rollover valve 1 8 Fue...

Page 380: ...el hose to fuel fil ter slide the fuel hose connector lock 3 in the direction of the arrow shown using a slotted head screwdriver and then disconnect the hose Disconnect the fuel hose from the fuel pu...

Page 381: ...ip a shall face toward the fuel tank Tighten the fuel pump bolts in the proper tight ening sequence as shown 2 Install Fuel hoses NOTICE ECA1TP1017 When installing a fuel hose make sure that it is sec...

Page 382: ...Install Fuel sender O ring TIP Position the fuel sender coupler 1 between the guides a on the fuel tank bracket 2 A Connection to fuel pump and fuel filter B Connection between fuel hoses T R Fuel se...

Page 383: ...ler 1 Disconnect 2 Intake air pressure sensor hose 1 Disconnect 3 Throttle cable 2 Disconnect 4 Throttle body 1 NOTICE ECA1TP1018 The throttle body should not disassem bled 5 Gasket 1 6 ISC idle speed...

Page 384: ...6 1 Engine temperature sensor coupler 1 Disconnect 2 Fuel injector coupler 2 Disconnect 3 Fuel filter 1 4 Fuel filter cover 1 5 Fuel return hose 1 6 Intake manifold joint clamp screw 2 Loosen 7 Intake...

Page 385: ...ove Q ty Remarks 1 Pressure regulator 1 2 Inlet pipe assembly 1 3 Injector 2 4 Intake manifold 1 For assembly reverse the disassembly pro cedure LT New New New New New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T...

Page 386: ...he bolts from being tightened to the specified torque 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 7 39 EAS1TP1041 INSTALLING THE INJECTORS 1 Install the injectors...

Page 387: ...Measure the throttle position sensor output voltage e Adjust the throttle position sensor angle so that the output voltage is within the specified range f After adjusting the throttle position sensor...

Page 388: ...intake manifold joint 2 to the intake manifold assembly TIP Be sure to fit the projection b on the intake manifold assembly between the projections c on the rear cylinder intake manifold joint c Inst...

Page 389: ...RAM for ABS models 7 19 TROUBLESHOOTING 7 21 LIGHTING SYSTEM 7 23 CIRCUIT DIAGRAM except for ABS models 7 23 CIRCUIT DIAGRAM for ABS models 7 25 TROUBLESHOOTING 7 27 SIGNALING SYSTEM 7 29 CIRCUIT DIAG...

Page 390: ...7 111 ABS COUPLER LOCATION CHART 7 113 MAINTENANCE OF THE ABS ECU 7 115 ABS TROUBLESHOOTING OUTLINE 7 115 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 7 116 BASIC PROCESS FOR TROUBLESHOOTING 7 117 A CHECKIN...

Page 391: ...POSITION SENSOR 7 163 CHECKING THE LEAN ANGLE SENSOR 7 163 CHECKING THE STARTER MOTOR OPERATION 7 164 CHECKING THE STATOR COIL 7 164 CHECKING THE RECTIFIER REGULATOR 7 165 CHECKING THE OIL LEVEL SWIT...

Page 392: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Page 393: ...ay unit 19 Neutral switch 20 Sidestand switch 25 Crankshaft position sensor 26 Lean angle sensor 31 ECU engine control unit 32 Front cylinder ignition coil 33 Spark plug 34 Rear cylinder ignition coil...

Page 394: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Page 395: ...ition fuse 24 Relay unit 27 Neutral switch 28 Sidestand switch 32 Crankshaft position sensor 33 Lean angle sensor 38 ECU engine control unit 39 Front cylinder ignition coil 40 Spark plug 41 Rear cylin...

Page 396: ...venting the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sid...

Page 397: ...ING THE BATTERY on page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Regap or replace the spark plug s 4 Chec...

Page 398: ...n page 7 151 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELA...

Page 399: ...IGNITION SYSTEM 7 8...

Page 400: ...B L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L...

Page 401: ...rter relay 9 Starter motor 10 Ignition fuse 16 Relay unit 17 Starting circuit cut off relay 19 Neutral switch 20 Sidestand switch 50 Joint coupler 58 Clutch switch 71 Engine stop switch 72 Start switc...

Page 402: ...L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L...

Page 403: ...rter relay 9 Starter motor 13 Joint coupler 17 Ignition fuse 24 Relay unit 25 Starting circuit cut off relay 27 Neutral switch 28 Sidestand switch 65 Clutch switch 78 Engine stop switch 79 Start switc...

Page 404: ...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...

Page 405: ...harge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 164 The starter motor is OK Perform the elec tric starting system troubleshoot...

Page 406: ...51 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page...

Page 407: ...ELECTRIC STARTING SYSTEM 7 16...

Page 408: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Page 409: ...CHARGING SYSTEM 7 18 1 AC magneto 2 Rectifier regulator 4 Main fuse 5 Battery A Wire harness B Negative battery sub wire harness...

Page 410: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Page 411: ...CHARGING SYSTEM 7 20 1 AC magneto 2 Rectifier regulator 4 Main fuse 5 Battery A Wire harness B Negative battery sub wire harness...

Page 412: ...n page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 164 Replace the crankshaft position sen sor stator assembly...

Page 413: ...CHARGING SYSTEM 7 22...

Page 414: ...Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Page 415: ...unit 41 Multi function meter 45 Meter light 46 High beam indicator light 50 Joint coupler 52 Headlight relay 54 Dimmer switch 55 Pass switch 61 Headlight 62 Auxiliary light 67 License plate light 68 T...

Page 416: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Page 417: ...U engine control unit 48 Multi function meter 52 Meter light 54 High beam indicator light 59 Headlight relay 61 Dimmer switch 62 Pass switch 68 Headlight 69 Auxiliary light 74 License plate light 75 T...

Page 418: ...on and signaling system Refer to CHECKING THE FUS ES on page 7 155 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 156 Clean the battery terminals Recharge...

Page 419: ...e entire lighting system wiring Refer to CIRCUIT DIAGRAM ex cept for ABS models on page 7 23 and CIRCUIT DIAGRAM for ABS models on page 7 25 Properly connect or replace the wire har ness Replace the E...

Page 420: ...G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Page 421: ...warning light 48 Turn signal indicator light 49 Fuel sender 50 Joint coupler 51 Turn signal hazard relay 56 Turn signal switch 57 Horn switch 60 Horn 63 Front left turn signal light 64 Front right tur...

Page 422: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Page 423: ...ter 50 Oil level warning light 51 Fuel level warning light 56 Turn signal indicator light 57 Fuel sender 58 Turn signal hazard relay 63 Turn signal switch 64 Horn switch 67 Horn 70 Front left turn sig...

Page 424: ...em hazard light ing and ABS ECU for ABS mod els Refer to CHECKING THE FUS ES on page 7 155 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 156 Clean the bat...

Page 425: ...e 1 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 15...

Page 426: ...ABS models on page 7 29 and CIRCUIT DIAGRAM for ABS models on page 7 31 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITC...

Page 427: ...eplace the fuel sender 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for ABS models on page 7 29 and CIRCUIT DIAGRAM for ABS models on page 7 31 Properly connect or repla...

Page 428: ...CU coupler white white white red white red Between ABS ECU coupler and ECU coupler white yellow white yellow Between ECU coupler and meter assembly coupler yellow blue yellow blue 2 Check the entire w...

Page 429: ...SIGNALING SYSTEM 7 38...

Page 430: ...L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G...

Page 431: ...ensor 26 Lean angle sensor 27 Throttle position sensor 28 Intake air pressure sensor 29 ISC idle speed control unit 30 Yamaha diagnostic tool coupler 31 ECU engine control unit 32 Front cylinder ignit...

Page 432: ...L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L...

Page 433: ...ir temperature sensor 32 Crankshaft position sensor 33 Lean angle sensor 34 Throttle position sensor 35 Intake air pressure sensor 36 ISC idle speed control unit 37 Yamaha diagnostic tool coupler 38 E...

Page 434: ...low is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to ON and i...

Page 435: ...de number is dis played 5 Erase the malfunction history in the diagnos tic mode code No 62 Refer to SELF DI AGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 8 5 TIP Turning the main switch to OFF w...

Page 436: ...sting the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap 1 and then connect the Yamaha diagnostic tool to the coupler TIP When the Yamaha diagnostic tool is connected...

Page 437: ...t of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code num...

Page 438: ...isplay freeze frame data The mark is displayed when the freeze frame data is available 10 ECU conduction time hour minute second The total ECU conduction time total hours the vehicle s main switch was...

Page 439: ...onfirmation of service completion 1 Connection of crankshaft po sition sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and...

Page 440: ...ntake air pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected...

Page 441: ...yed Go to item 6 6 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated A...

Page 442: ...condition Clogged or detached hose Repair or replace the sen sor hose Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code n...

Page 443: ...locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace th...

Page 444: ...d with the transmission in gear Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of sidestand switch coupler Check the locking condition of...

Page 445: ...witch coupler and relay unit cou pler blue green blue green Between relay unit and ECU coupler blue yellow blue black Turn the main switch to ON and then extend and retract the sidestand Fault code nu...

Page 446: ...isconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switc...

Page 447: ...rocedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Installed condition of O2 sen sor Improperly installed sensor Reinstall or replace the senso...

Page 448: ...3 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Check fuel pressure Refer to CHECKING THE PRESSURE REGULATOR OPERATION on page 6 9 Start the en...

Page 449: ...engine temperature sensor coupler and ECU coupler brown brown Between engine temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black...

Page 450: ...the sensor Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor...

Page 451: ...played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between front cylinder igni tion coil coupler and ECU coupler orange orange Start the engine and let it i...

Page 452: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repla...

Page 453: ...rol valve and then fully opens the valve ISC operating sound is heard Go to item 2 ISC operating sound is not heard Go to item 2 in sec tion B for the defective ISC idle speed control unit 2 Incorrect...

Page 454: ...e system Able to start engine Able to drive vehicle Diagnostic code No 54 Actuation Fully closes the ISC valve and then opens the valve This opera tion is performed 3 times and takes approximately 4 s...

Page 455: ...SC idle speed control coupler and ECU coupler red green red green pink blue pink blue white green white green brown brown Between ISC idle speed control coupler and relay unit coupler red black red bl...

Page 456: ...ool screen come on each time the fuel injector is actuated Procedure Check that front cylinder injector is actuated five times by listening for the operating sound 37 Actuation Actuates the rear cylin...

Page 457: ...bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code Nos 36 37 No operating sound Go to...

Page 458: ...Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis p...

Page 459: ...indi cated value increases Value does not increase Go to item 2 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re...

Page 460: ...speed sensor cou pler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Execute the diagnostic mode Code No 07 Rotate the rear whe...

Page 461: ...increases Value does not increase Go to item 2 in section A for the speed sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the...

Page 462: ...Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item 9 Incorrect indication Go to item 5 5 Defective re...

Page 463: ...e number is not displayed Fault code No 42 Except for ABS models Item A Speed sensor no normal signals are received from the speed sensor B Neutral switch open or short circuit is detected C Clutch sw...

Page 464: ...the transmission is in gear with the clutch lever is released and the sidestand retracted OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 3 3 C...

Page 465: ...ezed ON Correct indication Go to item 9 Incorrect indication Go to item 6 6 Wire harness continuity Between clutch switch cou pler and relay unit coupler blue yellow black yellow When the clutch lever...

Page 466: ...umulative and does not reset each time the wheel is stopped Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagno...

Page 467: ...not increase Go to item 4 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins...

Page 468: ...not displayed Fault code No 42 For ABS models Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch ope...

Page 469: ...Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the...

Page 470: ...ased OFF Correct indication Go to item 9 Incorrect indication Go to item 6 6 Defective neutral switch Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 151 Execute the diagnostic mode...

Page 471: ...ransmission clutch lever and sidestand Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagnostic mode Code No 07...

Page 472: ...Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagn...

Page 473: ...he clutch lever is released and the sidestand retracted OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 8 8 Malfunction in ECU Replace the ECU...

Page 474: ...t code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Page 475: ...ted in diagnostic mode code No 60 EE PROM data error for adjust ment of CO concentration of cylinder 1 Change the CO concentra tion of cylinder 1 and re write in EEPROM Refer to ADJUSTING THE EXHAUST...

Page 476: ...dis played Repeat the mainte nance job Fault code No 50 Item Faulty ECU engine control unit memory When this malfunc tion is detected in the ECU the fault code number might not appear Fail safe syste...

Page 477: ...ed Service is finished Fault code number is dis played Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code number is not dis played Service is fini...

Page 478: ...or data from the ECU cannot be received correctly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of mal function and check Maint...

Page 479: ...tion of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har nes...

Page 480: ...switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 4 Item ECU engine control unit...

Page 481: ...FUEL INJECTION SYSTEM 7 90...

Page 482: ...G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B B...

Page 483: ...ch 4 Main fuse 5 Battery 7 Fuel injection system fuse 10 Ignition fuse 16 Relay unit 18 Fuel pump relay 31 ECU engine control unit 37 Fuel pump 50 Joint coupler 71 Engine stop switch A Wire harness B...

Page 484: ...R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L L...

Page 485: ...h 4 Main fuse 5 Battery 10 Fuel injection system fuse 13 Joint coupler 17 Ignition fuse 24 Relay unit 26 Fuel pump relay 38 ECU engine control unit 44 Fuel pump 78 Engine stop switch A Wire harness B...

Page 486: ...ery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 151 The engine...

Page 487: ...FUEL PUMP SYSTEM 7 96...

Page 488: ...y G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L R W R B B R B B B B Gy R Br L R Br Br R Br R R B R W L B B L R B R W Y L Lg R B B R L W R L Sb W B Y L Y L G L R L R G Sb L W L B B L G B B...

Page 489: ...5 Battery 7 Fuel injection system fuse 10 Ignition fuse 13 Backup fuse 15 Immobilizer unit 31 ECU engine control unit 41 Multi function meter 47 Immobilizer system indicator light 50 Joint coupler A...

Page 490: ...L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y B Y B Y L L L...

Page 491: ...5 Battery 10 Fuel injection system fuse 13 Joint coupler 17 Ignition fuse 21 Backup fuse 23 Immobilizer unit 38 ECU engine control unit 48 Multi function meter 55 Immobilizer system indicator light A...

Page 492: ...ering key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard ke...

Page 493: ...Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hour...

Page 494: ...ch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key...

Page 495: ...Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Im...

Page 496: ...AND CHARGING THE BATTERY on page 7 156 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 151 Replace the main switch immobil...

Page 497: ...ey 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted be tween the ECU and the immobil...

Page 498: ...seconds Units of 1 Cycles of on for 0 5 second and off for 0 5 second Example fault code 52 56 ECU Unidentified code is received Noise interference or disconnected lead ca ble 1 Check the wire harness...

Page 499: ...IMMOBILIZER SYSTEM 7 108...

Page 500: ...L Y G B L B R Br Y B L L L L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R R B R B R W L B R G Y Sb P B L W R B Br W L R L B B Y B W...

Page 501: ...pler 14 Front wheel sensor 15 Rear wheel sensor 16 ABS test coupler 17 Ignition fuse 18 ABS ECU fuse 19 Signaling system fuse 38 ECU engine control unit 48 Multi function meter 53 ABS warning light 75...

Page 502: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 111 EAS27740 ABS COMPONENTS CHART 1 2 3 4 6 7 8 9 10 11 12 5 5...

Page 503: ...S motor fuse 2 ABS test coupler 3 ABS ECU fuse 4 ABS solenoid fuse 5 Hydraulic unit assembly 6 ABS warning light 7 Front brake caliper 8 Front wheel sensor 9 Front wheel sensor rotor 10 Rear brake cal...

Page 504: ...SYSTEM for ABS models 7 113 EAS27750 ABS COUPLER LOCATION CHART 1 2 4 5 L R L B B L R B 3 R G Y Sb P B L W R B Br W L R L B B Y B W W R W L G B W Y R B R G G B Sb W Y Lg Ch Dg B L Y L Y G P W W G Gy...

Page 505: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 114 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS test coupler 4 ABS ECU coupler 5 Front wheel sensor coupler...

Page 506: ...using the Yamaha diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 7 119 For troubleshooting items other than the following...

Page 507: ...bjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfu...

Page 508: ...ly Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The connection with the Yamaha diagnostic tool is defective The ABS ECU fuse is blown The ABS...

Page 509: ...defective Replace the hydraulic unit assembly EAS1XC1006 A 2 THE ABS WARNING LIGHT AND ALL OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING...

Page 510: ...ECU coupler and the ABS test coupler Check for continuity between the blue red terminal of the ABS ECU coupler and the blue red ter minal of the ABS test coupler Check for continuity between the blue...

Page 511: ...TI LOCK BRAKE SYSTEM for ABS models 7 120 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal ope...

Page 512: ...st of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displa...

Page 513: ...e received intermit tently while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor rotor or incorrect installa...

Page 514: ...wheel sensor and the hydraulic unit assembly Defective front wheel sensor or hydraulic unit assembly 16 Rear wheel sensor open or short circuit Open or short circuit is de tected in the rear wheel se...

Page 515: ...h circuit Defective signaling sys tem tail brake light or brake light switch Defective coupler be tween the signaling sys tem tail brake light or brake light switch and the hydraulic unit assem bly Op...

Page 516: ...the hydraulic pres sure Incorrect installation of the front wheel sensor Incorrect rotation of the front wheel Front brake dragging Defective hydraulic unit assembly 42 47 Rear wheel ABS intermit ten...

Page 517: ...nected battery terminal Defective charging sys tem 53 Vehicle system power supply voltage of ABS ECU power supply is low Power voltage supplied to the ABS ECU in the hy draulic unit assembly is too lo...

Page 518: ...ear wheel sensor and the hydraulic unit assem bly Defective rear wheel sensor Defective hydraulic unit assembly Fault code No Item Symptom Check point Fault code No 11 25 Item Front wheel sensor inter...

Page 519: ...sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if neces sary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and...

Page 520: ...or or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSO...

Page 521: ...r or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR for ABS mod els on page 4 26 Fault code No 15 Item Front wheel sensor open or short circuit Sy...

Page 522: ...between the black yellow terminal 3 and the blue terminal 4 and between the black yellow terminal 3 and the green terminal 5 If there is short circuit the wire harness is defec tive Replace the wire h...

Page 523: ...rminal 5 If there is no continuity the wire harness is defec tive Replace the wire harness Check that there is no short circuit between the white red terminal 1 and the white terminal 2 and between th...

Page 524: ...13 3 Defective sensor rotor or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FR...

Page 525: ...ls on page 4 26 Fault code No 21 Item Hydraulic unit assembly defective solenoid drive circuit Symptom Solenoid drive circuit in the hydraulic unit assembly is open or short circuited Order Item compo...

Page 526: ...rmal ABS solenoid power sup ply Symptom Power is not supplied to the solenoid circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS solen...

Page 527: ...y abnormal ABS motor power supply Symptom Power is not supplied to the motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS motor...

Page 528: ...use Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM for ABS models on page 4 61 Fault code No 41 Item Front wheel A...

Page 529: ...wheel sensor are received intermittently while the vehicle is traveling For fault code No 42 Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS E...

Page 530: ...nsor if neces sary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 13 3 Defective sensor rotor or incorr...

Page 531: ...OR for ABS mod els on page 4 26 4 Defective rear wheel sensor or incor rect installation of the sensor Check the wheel sensor for damage and the in stalled condition of the sensor Repair or replace th...

Page 532: ...between the battery and the hy draulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS ECU fuse brown white brown white 4 Defective charging system Check th...

Page 533: ...al data is detected in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to AB...

Page 534: ...ircuit between the black yellow terminal 3 and the blue terminal 1 If there is a short circuit the wire harness is de fective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective front wheel...

Page 535: ...rcuit between the black yellow terminal 3 and the white terminal 1 If there is a short circuit the wire harness is de fective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective rear wheel s...

Page 536: ...the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISC on page 4 17 and INSTALL ING THE REAR WHEEL REAR BRAKE DISC on page 4 27 3 Perform brake line routing co...

Page 537: ...ABS ANTI LOCK BRAKE SYSTEM for ABS models 7 146...

Page 538: ...ELECTRICAL COMPONENTS 7 147 EAS27970 ELECTRICAL COMPONENTS 3 1 2 6 4 9 10 11 12 13 14 16 7 5 8 15...

Page 539: ...ition coil 5 ABS ECU electronic control unit for ABS models 6 Turn signal hazard relay 7 ECU engine control unit 8 Rear wheel sensor for ABS models 9 Speed sensor except for ABS models 10 Neutral swit...

Page 540: ...ELECTRICAL COMPONENTS 7 149 1 2 5 7 10 8 9 6 16 15 14 13 4 3 11 12...

Page 541: ...unit 4 Battery 5 Lean angle sensor 6 Headlight relay 7 Starter relay 8 ABS motor fuse for ABS models 9 Fuel injection system fuse except for ABS models 10 Main fuse 11 Fuse box 1 12 Fuse box 2 for AB...

Page 542: ...AS27980 CHECKING THE SWITCHES 1 6 5 7 8 4 3 2 R Br P B W Br Y G R Y B Y Br W Dg P Br L O Ch L Y 14 15 12 13 11 ON OFF P R Br R Br Br R O L R Y O Dg Br W Ch R N L 10 9 Dg Br B Ch B B B P Y G B Y L W B...

Page 543: ...brake light switch 3 Reset switch 4 Select switch 5 Engine stop switch 6 Start switch 7 Hazard switch 8 Rear brake light switch 9 Neutral switch 10 Sidestand switch 11 Dimmer switch 12 Pass switch 13...

Page 544: ...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...

Page 545: ...the bulbs The following 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...

Page 546: ...ter selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verif...

Page 547: ...ifferent from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte l...

Page 548: ...contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery beco...

Page 549: ...e should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current...

Page 550: ...fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C A Except for ABS models B For ABS models 1 Positive battery terminal 2 Negative batte...

Page 551: ...ification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage 1 Positive ba...

Page 552: ...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...

Page 553: ...S The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket...

Page 554: ...oupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Re...

Page 555: ...e 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 spe...

Page 556: ...t of specification Replace the oil level switch a Connect the pocket tester 100 to the oil level switch terminal as shown b Measure the oil level switch resistance Charging voltage 14 V at 5000 r min...

Page 557: ...uel sender or thermistor Replace the fuel sender EAS1TP1011 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the oil level detection circuit 1 Check Oil le...

Page 558: ...the pocket tester 1 k to the en gine temperature sensor as shown b Measure the engine temperature sensor re sistance 3 Install Engine temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR...

Page 559: ...1 Remove Intake air temperature sensor WARNING EWA1TP1020 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air...

Page 560: ...1012 CHECKING THE FUEL INJECTORS The following procedure applies to all off the fuel injectors 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel in...

Page 561: ...MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 2 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEG...

Page 562: ...y fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged o...

Page 563: ...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 GE...

Page 564: ...damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper brac...

Page 565: ...ction Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty tur...

Page 566: ...ort circuit detected in the primary lead of the rear cylinder ignition coil 7 61 37 Component other than ISC idle speed control unit is defective ISC operating sound is heard 7 62 Defective ISC idle s...

Page 567: ...between the ECU and the multi function meter 7 85 Er 2 ECU engine control unit internal malfunction output signal error no signals are received from the ECU within the specified duration 7 86 Er 3 ECU...

Page 568: ...nd does not reset each time the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sensor and incline it more than 45 degrees Upright 0 4 1 4 Overturned 3 7 4...

Page 569: ...stand is extended OFF 60 EEPROM fault code dis play No history 00 No malfunctions detect ed If the self diagnosis fault code 44 is indicat ed the ECU is defec tive History exists 01 or 02 Cylinder fa...

Page 570: ...dure 30 Front cylinder ignition coil Actuates the front cylinder ignition coil five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen come on each time the ig...

Page 571: ...nostic tool screen go off When the relay is off the CHECK indicator and on the Yamaha diag nostic tool screen come on Check that the relay unit fuel pump relay is actuat ed five times by listening fo...

Page 572: ...lebar switch 54 Dimmer switch 55 Pass switch 56 Turn signal switch 57 Horn switch 58 Clutch switch 59 Passing light OPTION 60 Horn 61 Headlight 62 Auxiliary light 63 Front left turn signal light 64 Fr...

Page 573: ...der 58 Turn signal hazard relay 59 Headlight relay 60 Left handlebar switch 61 Dimmer switch 62 Pass switch 63 Turn signal switch 64 Horn switch 65 Clutch switch 66 Passing light OPTION 67 Horn 68 Hea...

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Page 577: ...L B L R R L Gy G Gy W L W R W B Y Br Br W L Y P W W Y B L B L B L L L L Y Y G G Y Gy B L B L B L B L B L B L B L B L Gy G Gy W R W B W B L Br Br W Br W Br W B Dg Ch Y G Ch Dg B L B R B B B B Gy R Br...

Page 578: ...excepto modelos con ABS 2014 DIAGRAMA EL CTRICO A ON OFF P R N L SELECT RESET C C E E E D D D D B L Y B A D F E C E A A D B C A A A B Gy B B B B B B B B Db B B B Gy Gy Db B B Gy Gy Gy B B B B Gy Gy B...

Page 579: ...W B Y Br W Br B Br W L Y B Y Br Ch Dg G L R Y B L G L G L G L Y G B L B R Br Y B L L L L L R W R W R W R W R L R L R G R G Br W Br W Br W Br W G L R Y Y Y Y Y B W B B B B R B R Br L R Br Br R Br R R R...

Page 580: ...A A ON OFF P R N L SELECT RESET C C E E E D D D D S B A D F E C E A A D B C A A A B Gy B B B B B B B B B B B B B Gy Gy B B Gy Gy Gy B B B B Gy Gy B B Gy B Gy B B B B B B Db B B B B Gy B Gy 2 3 4 5 6 7...

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