Yamaha YZF-R1(B) 2012 Service Manual Download Page 1

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SERVICE MANUAL

YZF-R1(B)

2012

1KB-28197-E0

Summary of Contents for YZF-R1(B) 2012

Page 1: ...SERVICE MANUAL YZF R1 B 2012 1KB 28197 E0...

Page 2: ...ZF R1 B SERVICE MANUAL 2011 by Yamaha Motor Co Ltd First edition July 2011 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly p...

Page 3: ...significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP Designs and specification...

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

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

Page 8: ......

Page 9: ...Chip Controlled Intake 1 4 OUTLINE OF THE TCS Traction Control System 1 8 INSTRUMENT FUNCTIONS 1 12 IMPORTANT INFORMATION 1 20 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 20 REPLACEMENT PARTS 1 20 GASK...

Page 10: ...ICATION 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 seat rail reinforcement under the p...

Page 11: ...gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection...

Page 12: ...oolant temperature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor air temperature sensor rear speed sensor an...

Page 13: ...um volume of intake air for easy to use torque even in a high revving engine The YCC I system calculates the value from the engine speed and throttle opening rate activates the intake air funnel with...

Page 14: ...CC I offers higher levels of power across the RPM range Electronically controlled intake length The YCC I system consists of four lightweight plastic resin funnels and each of these is divided into an...

Page 15: ...river 8 Throttle servo motor driver operation sens ing shut off circuit 9 Throttle servo motor driver operation sens ing feedback emergency stop 10 Emergency stop 11 Engine revolution pulse signal 12...

Page 16: ...Atmospheric pressure sensor 9 Accelerator position two signals 10 Throttle position two signals 11 Engine revolution 12 Vehicle speed 13 Coolant temperature 14 Neutral In gear 15 Atmospheric pressure...

Page 17: ...slipping exceeds the preset value the ECU controls the slipping using integrated control of the ignition timing fuel cut off and throttle valve opening of the YCC T system The traction control system...

Page 18: ...n is restored The traction control system indicator warning light flashes to let the rider know that traction control has engaged WARNING EWA23P1039 The traction control system is not a substitute for...

Page 19: ...ystem cannot be turned on or off while the vehicle is moving ECA23P1085 Use only the specified tires Using different sized tires will prevent the traction control sys tem from controlling tire rotatio...

Page 20: ...nd the system will be enabled The engine trouble warning light should go off after the motorcycle reaches at least 20 km h 12 mi h If the traction control system indicator warning light and or engine...

Page 21: ...timing indicator light control mode TIP Be sure to turn the key to ON before using the SELECT and RESET buttons except for setting the display brightness and shift timing indicator light control mode...

Page 22: ...stop the stopwatch and display the final split time Split time history The split time history displays up to 20 stored split times The split time history can be dis played either in reverse chronologi...

Page 23: ...point In that case push the SELECT button to switch the display between the various tripmeter odome ter instantaneous fuel consumption and aver age fuel consumption modes in the following order TRIP...

Page 24: ...e second when one of the displays is shown To reset the average fuel consumption display select it by pushing the SELECT button and then push the RESET button for at least one second TIP After resetti...

Page 25: ...display is selected A is displayed before the temper ature Traction control system mode display This display indicates which traction control system mode has been selected For more details on the mod...

Page 26: ...indicator light activation This function allows you to select the engine speed at which the indicator light is activated d Shift timing indicator light deactivation This function allows you to select...

Page 27: ...se the shift timing indicator light remains deactivated 1 Push the RESET button to select the desired engine speed for deactivating the indicator light 2 Push the SELECT button to confirm the selected...

Page 28: ...A or B in the following order STD A B STD The throttle grip must be completely closed in order to change the drive mode TIP The mode is set to STD by default The STD mode resets when the key is turne...

Page 29: ...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 30: ...d grease Oil bearings liberally when installing if appro priate ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly c...

Page 31: ...al times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 C...

Page 32: ...ctricity and it s voltage is very high and electronic parts is very sensitive It has possibility that inside small parts of elec tronic parts is destroyed by static electricity Do not touch and do not...

Page 33: ...epending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number star...

Page 34: ...er rod holder 90890 01506 YM 01506 4 65 4 67 Oil filter wrench 90890 01426 YU 38411 3 29 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 64 4 69 Rod puller 90890 01437 Universal dampi...

Page 35: ...g compressor 90890 01441 YM 01441 4 64 4 69 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 67 4 68 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 10 Compress...

Page 36: ...compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 29 5 35 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 14 Mechanical seal installer...

Page 37: ...mm YM 04098 5 31 Valve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 31 Valve guide reamer 5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 31 Valve guide reamer 4 5 90890...

Page 38: ...essure adapter H 90890 03139 3 30 Pressure gauge 90890 03153 YU 03153 3 30 7 18 Fuel pressure adapter 90890 03176 YM 03176 7 18 Fuel injector pressure adapter 90890 03210 YU 03210 7 18 Camshaft wrench...

Page 39: ...7 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 37 5 40 5 41 5 43 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 22 8 127 8 128 8 129 8 133 8 134 8 135 8 136 8 137 8 138 8...

Page 40: ...03208 8 141 8 146 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 138 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 145 8 146 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 2...

Page 41: ...ORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 26 LUBRICATIO...

Page 42: ...L PRT SVN SWE ZAF 1KB9 1KBK BEL FRA 1KBH 1KBP AUS Dimensions Overall length 2070 mm 81 5 in Overall width 715 mm 28 1 in Overall height 1130 mm 44 5 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55...

Page 43: ...4 58 L 4 84 US qt 4 03 Imp qt Without oil filter cartridge replacement 3 73 L 3 94 US qt 3 28 Imp qt With oil filter cartridge replacement 3 93 L 4 15 US qt 3 46 Imp qt Oil filter Oil filter type Cart...

Page 44: ...Cylinder head Volume 14 43 15 23 cm 0 88 0 93 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 25 500 25 521 mm 1 0039 1 0048 in Camshaft jou...

Page 45: ...mm 0 0433 0 0512 in Limit 1 80 mm 0 07 in Valve margin thickness D intake 1 35 1 75 mm 0 0532 0 0689 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975...

Page 46: ...72 kgf 41 59 47 88 lbf Spring tilt limit intake 2 5 1 7 mm 0 067 in Spring tilt limit exhaust 2 5 1 7 mm 0 067 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 7...

Page 47: ...mm 0 0039 0 0157 in Connecting rod Crankshaft pin to big end bearing clearance 0 034 0 058 mm 0 0013 0 0023 in Limit 0 09 mm 0 0035 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Widt...

Page 48: ...2 533 38 15 2nd 2 063 33 16 3rd 1 762 37 21 4th 1 522 35 23 5th 1 364 30 22 6th 1 269 33 26 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Shift...

Page 49: ...output voltage OFF Less than 0 8 V Atmospheric pressure sensor output voltage 3 57 3 71 V at 101 32 kPa Intake air pressure sensor output voltage 3 57 3 71 V at 101 32 kPa Intake air temperature senso...

Page 50: ...Manufacturer model MICHELIN POWER PURE A 1KB8 1KB9 1KBJ 1KBK DUNLOP Qualifier II 1KB8 1KBH 1KBJ 1KBP Wear limit front 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Rear tire Type Tubeless Size 190 55 ZR17...

Page 51: ...pad lining thickness outer 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 18 mm 1 50 in Recommended fluid DOT 4 Steering Steeri...

Page 52: ...positions Minimum 16 Standard 8 Maximum 0 Rebound damping adjusting positions Minimum 20 Standard 15 Maximum 3 Compression damping setting for fast compression damping Minimum 4 Standard 3 Maximum 0...

Page 53: ...t circuit Rectifier regulator output voltage 14 2 14 8 V Rectifier regulator input voltage above 14 V at 5000 r min Rectifier capacity 50 0 A Lean angle sensor Lean angle sensor output voltage Less th...

Page 54: ...0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Horn Horn type Plane Quantity 1 pcs Maximum amperage 3 0 A Coil resistance 1 07 1 11 at 20 C 68 F...

Page 55: ...A Radiator fan fuse 10 0 A 2 Turn signal light fuse 7 5 A Fuel injection system fuse 15 0 A Steering damper fuse 7 5 A Backup fuse 7 5 A ETV Electronic Throttle Valve fuse 7 5 A Spare fuse 20 0 A Spar...

Page 56: ...To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi...

Page 57: ...gf 7 2 ft lbf Water pump inlet pipe bolt water pump side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water hose clamp 6 2 Nm 0 2 m kgf 1 4 ft...

Page 58: ...kgf 14 ft lbf Exhaust pipe and exhaust cham ber clamp bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Muffler and frame bolt M8 2 23 Nm 2 3 m kgf 17 ft lbf Muffler cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Exh...

Page 59: ...nel bracket bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Idler gear bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch holder bolt M6 3 14 Nm 1 4 m kgf 10 ft lbf Clutch boss nut M20 1 115 Nm 11 5 m kgf 85 ft...

Page 60: ...ap nut mating surface 2 Tighten the bolt to 20 Nm 2 0 m kgf 14 ft lbf 3 Retighten the bolt further to reach the specified angle of 145 155 TIP Crankcase bolt main journal 1 Lubricate the bolts thread...

Page 61: ...t lbf Rear shock absorber assembly lower nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly and bracket nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly bracket and frame...

Page 62: ...m kgf 5 1 ft lbf Rear fuel tank bracket and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank and rear fuel tank bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank upper cover and frame bolt...

Page 63: ...nment make sure to fit them by adding the external force by hand or with a plastic hammer etc Bleed screw master cylinder M8 1 6 Nm 0 6 m kgf 4 3 ft lbf Front wheel axle pinch bolt M8 4 21 Nm 2 1 m kg...

Page 64: ...he axle circumference is positioned on the end face of the fork At this stage it can be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order from t...

Page 65: ...read and washer Crankshaft sprocket bolt thread Balancer gear press fitting surface O rings coolant pipe Oil pump rotors inner and outer Shell Alvania EP Grease Oil cooler bolt thread and washer Oil f...

Page 66: ...2 25 Cylinder head cover semicircular Yamaha bond No 1215 Three bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Crankcase cover lead grommet Yamaha bond No 1215 Three bon...

Page 67: ...and rear shock absorber spacer Swingarm pivot shaft Swingarm pivot shaft bearings Swingarm dust cover lips Relay arm connecting arm and rear shock absorber oil seal lips Seat lock lever pivoting point...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART...

Page 69: ...il pump 3 Relief valve 4 Oil cooler 5 Sub gallery 6 Oil filter cartridge 7 Main gallery 8 Mission shower 9 Drive axle 10 Main axle 11 Shift fork upper 12 Crankshaft 13 Oil nozzle 14 Balancer shaft 15...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil filter cartridge 5 Oil level switch...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31...

Page 73: ...ION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Crankshaft 5 Balancer shaft 6 Oil cooler 7 Relief valve 8 Oil pipe 9 Oil strainer 10 Oil water pump a...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil level switch 3 Oil strainer 4 Oil pipe 5 Relief valve 6 Oil cooler...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil water pump assembly...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Oil delivery pipe 2 3 Drive axle...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Shift fork guide bar 2 Shift fork C 3 Shift drum assembly 4 Shift fork R 5 Drive axle 6 Shift fork L...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil nozzle 5 Crankshaft...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Balancer shaft 2 Crankshaft...

Page 86: ...COOLING SYSTEM DIAGRAMS 2 45 EAS20420 COOLING SYSTEM DIAGRAMS...

Page 87: ...COOLING SYSTEM DIAGRAMS 2 46 1 Oil water pump assembly 2 Radiator 3 Radiator fan 4 Thermostat 5 Oil cooler...

Page 88: ...COOLING SYSTEM DIAGRAMS 2 47...

Page 89: ...COOLING SYSTEM DIAGRAMS 2 48 1 Radiator cap 2 Radiator 3 Radiator fan 4 Oil cooler...

Page 90: ...CABLE ROUTING 2 49 EAS20430 CABLE ROUTING...

Page 91: ...fastening the headlight sub wire harness When fasten ing the headlight sub wire harness it should not be sagged Face the end of the clamp to front H Route the headlight lead toward the front of the me...

Page 92: ...CABLE ROUTING 2 51...

Page 93: ...the throttle cable above the lower bracket inside of the front fork and under the brake fluid reservoir hose Throttle cable accelerator cable and throttle cable decelerator cable should not be twiste...

Page 94: ...CABLE ROUTING 2 53...

Page 95: ...f the two slits at the root of the recti fier regulator bracket rib clamp at the back of the slit H Clamp the clutch cable and oil cooler outlet hose at the protector rivet ring of the clutch cable I...

Page 96: ...CABLE ROUTING 2 55...

Page 97: ...tion coil lead 2 Crankshaft position sensor lead 3 Rear brake light switch lead 4 O2 sensor lead A Route the rear brake light switch lead out side of the O2 sensor lead and push it to the occluding su...

Page 98: ...CABLE ROUTING 2 57...

Page 99: ...est assembly G The rear brake light switch lead should be directed as shown in the illustration H When installing the rear brake caliper bracket make sure to fit the torque recep tor convex of the rea...

Page 100: ...CABLE ROUTING 2 59...

Page 101: ...witch to the con nector bottom to up K Outside of the vehicle L Inside of the vehicle M Face the end of the clamp to front and inside of the vehicle N Order insignificant main switch lead steer ing da...

Page 102: ...CABLE ROUTING 2 61...

Page 103: ...idestand switch lead inside of the flange of the drive sprocket cover F 30 50 mm 1 18 1 97 in G Route the fuel tank breather hose fuel tank overflow hose and coolant reservoir breather hose inner side...

Page 104: ...CABLE ROUTING 2 63...

Page 105: ...arness such as the ground lead Route the fuel hose on the side of the main har ness facing toward rear of the vehicle H Route the main harness behind the crank case breather hose I Fasten the starter...

Page 106: ...CABLE ROUTING 2 65...

Page 107: ...nstall the coolant reservoir hose with the clamp opening facing up AE Fit the connector cover including the oil level switch lead gear position sensor lead rear speed sensor lead and side stand switch...

Page 108: ...CABLE ROUTING 2 67...

Page 109: ...turn signal light lead and left turn signal light lead through the guide of the battery box 2 route them between the ribs F When installing the seal align it to the push pin trace mark of the rear fra...

Page 110: ...CABLE ROUTING 2 69...

Page 111: ...reather hose with its white paint facing front of the vehicle H Install the fuel tank overflow hose with its yellow paint facing front of the vehicle I Install the fuel tank overflow hose and fuel tan...

Page 112: ...CABLE ROUTING 2 71...

Page 113: ...6 Primary injector 2 coupler 17 Primary injector 3 coupler 18 Primary injector 4 coupler 19 Cap A Checker color orange B Checker color black C Rotate the clip to the right of the vehicle D Adjust top...

Page 114: ...CABLE ROUTING 2 73...

Page 115: ...ic locking tie at the branch root of the sub wire harness Position the plastic locking tie as shown in the illustra tion F Position the sub wire harness under the bearing surface of the bolt so that i...

Page 116: ...CABLE ROUTING 2 75...

Page 117: ...E REAR DISC BRAKE 3 16 CHECKING THE REAR BRAKE PADS 3 17 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 17 CHECKING THE FRONT BRAKE HOSES 3 18 CHECKING THE REAR BRAKE HOSE 3 19 CHECKING THE WHEELS 3 19 CHECKIN...

Page 118: ...LIGHT SWITCH 3 33 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 33 CHECKING AND LUBRICATING THE CABLES 3 34 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 34 LUBRICATING THE REAR SUSPENSION 3 34 CHECKING AND CHAR...

Page 119: ......

Page 120: ...lometer based maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an ast...

Page 121: ...lay Lubricate with lithium soap based grease Every 50000 km 30000 mi 10 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughl...

Page 122: ...r damaged 22 Rear suspension relay arm and con necting arm pivot ing points Check operation 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter cartridge Replace 25 C...

Page 123: ...l tank breather hose is routed correctly 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1114 CHECKING THE FUEL LINE Secondary inject...

Page 124: ...e spark plug and gasket surface 11 Install Ignition coil 12 Install Air filter case Refer to AIR FILTER CASE on page 7 5 13 Install Fuel tank Refer to FUEL TANK on page 7 1 14 Install Lower cowlings S...

Page 125: ...nce is incorrect record the measured reading Measure the valve clearance in the following sequence a Turn the crankshaft clockwise and align the pickup rotor K mark a and crankcase occluding surface b...

Page 126: ...3 with a thickness gauge f Turn the crankshaft 180 degrees in clock wise and position the pickup rotor T mark a upward g Measure the valve clearance 2 with a thickness gauge h Turn the crankshaft 90...

Page 127: ...easured valve clearance 0 23 mm 0 0091 in 0 23 mm 0 0091 in 0 20 mm 0 0079 in 0 03 mm 0 0012 in c Check the thickness of the current valve pad TIP The thickness a of each valve pad is marked in hundre...

Page 128: ...he valve clearance is still out of specifi cation repeat all of the valve clearance adjustment steps until the specified clear ance is obtained 7 Install All removed parts TIP For installation reverse...

Page 129: ...e bodies by turning their bypass air screw in or out ECA14B1039 Do not turns the bypass air screw at the throttle body which is the base for synchro nizing otherwise the engine may run roughly at idle...

Page 130: ...Refer to FUEL TANK on page 7 1 3 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly ECA13450 Make sure the crankcase breather hose is routed correctly 4 Install Fu...

Page 131: ...and continue to press the buttons for 8 seconds or more TIP dIAG appears on the odometer tripmeter and fuel reserve trip LCD 3 Press the SELECT button to select the CO adjustment mode CO or the diagn...

Page 132: ...the SELECT button 8 Release the button to execute the selec tion 9 Simultaneously press the SELECT and RESET buttons to return to the cylinder selection step 5 10 Turn the main switch to OFF to cance...

Page 133: ...der seat Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust 2 Adjust Clutch cable free play Handlebar side...

Page 134: ...level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fl...

Page 135: ...e system Air in the brake system will considerably reduce in loss of control and possibly an accident Therefore check and if necessary bleed the brake system ECA13490 After adjusting the brake lever p...

Page 136: ...ce the brake pads as a set Refer to REAR BRAKE on page 4 44 EAS21360 BLEEDING THE HYDRAULIC BRAKE SYS TEM WARNING EWA13100 Bleed the hydraulic brake system when ever the system is disassembled a brake...

Page 137: ...l of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brak...

Page 138: ...heck Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or replaced always balance the wheel EAS21650 CHECKING...

Page 139: ...ion mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Tire air pressure measured on cold tires Loading condition 0 90...

Page 140: ...can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the veh...

Page 141: ...ns Do not use any other lubricants on the drive chain since they may contain sol vents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level s...

Page 142: ...t Refer to HANDLEBARS on page 4 56 EAS14B1092 CHECKING THE STEERING DAMPER Refer to CHECKING THE STEERING DAMPER on page 4 75 EAS14B1093 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts an...

Page 143: ...n Replace the defec tive part s EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS14B1095 CHECKING THE SIDESTAND SWITCH Refer to ELECT...

Page 144: ...Adjust Spring preload a Turn the adjusting bolt 1 in direction a or b Rebound damping ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping right side a Turn th...

Page 145: ...mum adjustment positions 1 Adjust Spring preload a Adjust the spring preload with a spring pre load adjusting bolt b Turn the spring preload adjusting bolt 1 in direction a or b Direction a Compressio...

Page 146: ...sion damping ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping for slow com pression damping Direction a Rebound damping is increased suspension is hard...

Page 147: ...clutch and the wrong oil types 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 labeled ENERGY C...

Page 148: ...following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of lithium soap based grease ECA13390 Make...

Page 149: ...o increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are extremely hot 4 Install...

Page 150: ...ailable soft water may be used 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EA...

Page 151: ...terclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 5 Remove Coolant drain bolt engine 1 along with the copper washer 6 Drain Coolant from the e...

Page 152: ...it up for several minutes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 31 TIP Before checking the coolant level wait a few minutes until the coolant has settl...

Page 153: ...ation Adjust 2 Adjust Throttle cable free play a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut 1 WA...

Page 154: ...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 headlight bulb gets soiled thoroughly...

Page 155: ...NTENANCE 3 36 Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headlight beam moves to the left Direction b Headlight beam moves t...

Page 156: ...PERIODIC MAINTENANCE 3 37...

Page 157: ...IR DUCT COVERS 4 13 INSTALLING THE INTAKE AIR DUCT COVERS 4 13 INSTALLING THE AIR INTAKE DUCTS 4 13 INSTALLING THE REAR VIEW MIRRORS 4 13 REMOVING THE WINDSHIELD 4 14 INSTALLING THE WINDSHIELD 4 14 IN...

Page 158: ...REAR BRAKE CALIPER 4 51 DISASSEMBLING THE REAR BRAKE CALIPER 4 51 CHECKING THE REAR BRAKE CALIPER 4 51 ASSEMBLING THE REAR BRAKE CALIPER 4 52 INSTALLING THE REAR BRAKE CALIPER 4 52 REMOVING THE REAR B...

Page 159: ...CTING ARM AND RELAY ARM 4 78 INSTALLING THE RELAY ARM 4 78 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 78 SWINGARM 4 80 REMOVING THE SWINGARM 4 82 CHECKING THE SWINGARM 4 83 INSTALLING THE SWINGARM...

Page 160: ...emove Q ty Remarks Fuel tank side cover Refer to FUEL TANK on page 7 1 1 Rider seat 1 2 Passenger seat 1 3 Battery negative lead 1 Disconnect 4 Tool band 1 5 Tool 1 6 Battery cover 1 7 Battery positiv...

Page 161: ...r Job Parts to remove Q ty Remarks 1 Front cowling inner panel 2 2 Side cowling 2 3 Front turn signal light coupler 2 Disconnect 4 Front turn signal light 2 5 Lower cowling 2 6 Side cowling inner pane...

Page 162: ...ASSIS on page 4 1 1 ECU coupler 2 Disconnect 2 ECU 1 3 Radiator fan motor relay coupler 1 Disconnect 4 Radiator fan motor relay 1 5 ECU bracket 1 6 Rectifier regulator coupler 1 Disconnect 7 Stator co...

Page 163: ...s Side cowling Refer to GENERAL CHASSIS on page 4 1 1 Air chamber cover 2 2 Air chamber 2 3 Air chamber bracket 2 4 Air intake air duct cover 2 5 Rear intake air duct upper 2 6 Rear intake air duct lo...

Page 164: ...ing Refer to GENERAL CHASSIS on page 4 1 Air duct Refer to GENERAL CHASSIS on page 4 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Auxiliary light coupler 2 Disconnect 3 Headlight sub wire...

Page 165: ...ENERAL CHASSIS on page 4 1 Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 1 Rear view mirror 2 2 Meter bracket 1 3 Meter coupler 1 Disconnect 4 Meter assembly 1 5 Headlight coupler 1 Disc...

Page 166: ...emove Q ty Remarks 11 Windshield 1 12 Windshield inner panel 1 13 Intake air temperature sensor 1 14 Headlight assembly 1 15 Front cowling 1 16 Headlight bulb cover 2 17 Headlight bulb coupler 2 Disco...

Page 167: ...lock assembly 1 2 Passenger seat lock cable 1 3 Passenger seat lock key cylinder 1 4 Upper tail cover 1 5 Lower tail cover bracket 1 6 Rear turn signal light lead connector 4 Disconnect 7 License plat...

Page 168: ...embly Order Job Parts to remove Q ty Remarks 1 License plate turn signal light stay 1 2 License plate turn signal light stay plate 1 3 Cover 1 4 Rear turn signal light 2 5 License plate light 1 6 Rear...

Page 169: ...th a screwdriver Make sure that the screw is flush with the fastener s head EAS14B1031 REMOVING THE QUICK FASTENER PUSH TYPE TIP To remove the quick fastener push its center with a screwdriver then pu...

Page 170: ...ock stay 2 Lock spring 3 TIP Align the projection a of the passenger seat lock key cylinder 1 to the grooves b of the lower tail cover and lock stay 2 and install EAS14B1038 REMOVING THE FRONT TURN SI...

Page 171: ...Side cowling inner panel 1 TIP When removing the side cowling inner panel downward pull out the side cowling inner panel hole from the projection a of the air chamber cover 2 EAS14B1043 INSTALLING THE...

Page 172: ...KE AIR DUCT COV ERS 1 Install Intake air duct cover 1 TIP Align the intake air duct cover tabs a and the tab b of the front cowling 2 as shown in the illustration and install EAS14B1048 INSTALLING THE...

Page 173: ...ling 2 EAS14B1051 INSTALLING THE MIRROR FITTING PLATES 1 Install Mirror fitting plate 1 to meter bracket 2 TIP Face the mirror fitting plate concave a up and install it to the meter bracket EAS14B1001...

Page 174: ...ners on the upper tail cover d Install the bolt on the upper tail cover 2 Install Passenger seat Refer to GENERAL CHASSIS on page 4 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1054 INSTALL...

Page 175: ...djusting the left and right rider footrest be sure to set them on the same level e Install the rider footrest bolts TIP Install the end a of the exhaust chamber cover 1 within the range b of the exhau...

Page 176: ...upler 1 Disconnect 2 Left brake hose holder 1 3 Front speed sensor 1 4 Right brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 Loosen 8 Fro...

Page 177: ...T WHEEL 4 18 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 For assembly reverse the disassembly pro ce...

Page 178: ...Front speed sensor Left brake caliper Right brake caliper TIP Remove the front speed sensor first to pre vent damage to the front speed sensor Do not apply the brake lever when removing the brake cali...

Page 179: ...l bearing outer race e Install the spacer f Install the new wheel bearing right side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 a...

Page 180: ...Measure the front speed sensor rotor deflection 2 0 mm 0 08 in below the edge of the front speed sensor rotor 4 Adjust Front speed sensor rotor deflection a Remove the front speed sensor rotor b Rota...

Page 181: ...wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the botto...

Page 182: ...r rotor only on the left side align the arrow 1 on the brake disc arrow 2 on the front speed sensor rotor and arrow 3 on the front wheel in the direction of wheel rotation Tighten the brake disc bolts...

Page 183: ...ctive part TIP Before measuring the distance between the front speed sensor rotor and front speed sensor remove the brake caliper Measure the distance between the front speed sensor rotor and front sp...

Page 184: ...iper Refer to REAR BRAKE on page 4 44 1 Locknut left and right 2 Loosen 2 Adjusting bolt left and right 2 Loosen 3 Rear wheel axle nut 1 4 Washer 1 5 Rear wheel axle 1 6 Adjusting block left 1 7 Adjus...

Page 185: ...eel sprocket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Oil seal 1 5 Bearing 1 6 Rear wheel drive hub 1 7 Rear wheel drive hub damper 6 8 Rear whee...

Page 186: ...EAR WHEEL 4 27 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedur...

Page 187: ...ts 2 4 Remove Wheel axle nut 1 Wheel axle Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel dr...

Page 188: ...amage Replace Rear wheel drive hub dampers 2 Damage wear Replace EAS14B1003 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth a wear Replace the drive chai...

Page 189: ...le Wheel bearings Oil seal lips 2 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 3 Tighten Rear wheel axle nut Rear brake caliper bolts WARNING EWA13530 Proper brake ho...

Page 190: ...ollowing procedure applies to both of the front brake calipers Front speed sensor Refer to FRONT WHEEL on page 4 17 1 Brake hose holder 1 Right side 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake...

Page 191: ...ervoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch con...

Page 192: ...33 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For installation reverse the remov...

Page 193: ...applies to both of the front brake calipers Front speed sensor Refer to FRONT WHEEL on page 4 17 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 1 Brake hose holder 1 Righ...

Page 194: ...Job Parts to remove Q ty Remarks 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Brake pad kit 1 5 Brake caliper piston 6 6 Brake caliper piston dust seal 6 7 Brake caliper piston seal 6 8...

Page 195: ...2240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 17 2 Check Brake discs Damage galling Replace 3 Measure Brak...

Page 196: ...a through d until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc 6 Install Front wheel Refer to FRONT WH...

Page 197: ...brake pad springs TIP The arrow mark a on the brake pad springs must point in the direction of disc rotation 6 Install Brake pad pins Brake pad clips Brake caliper Front speed sensor Brake hose holder...

Page 198: ...t the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston dust sea...

Page 199: ...ssem bled replace the brake caliper piston dust seals and brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake calipers 1 Insta...

Page 200: ...parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 5 Check Brake fluid level Below the minimum level mark...

Page 201: ...ONT BRAKE MAS TER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake compo...

Page 202: ...t is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoi...

Page 203: ...ing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad kit 1 6 Bleed screw 1 7 Brake pad spring 1 For ins...

Page 204: ...C BRAKE SYSTEM on page 3 17 1 Footrest plate 1 2 Brake fluid reservoir cap 1 3 Rear brake fluid reservoir diaphragm holder 1 4 Rear brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 B...

Page 205: ...inder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Adjusting nut 1 3 Brake master cylinder kit 1 4 Dust cover 1 5 Circlip 1 6 Hose joint 1 7 O ring 1 8 Brake master cylinder...

Page 206: ...REAR BRAKE 4 47 Removing the rear brake calipers Order Job Parts to remove Q ty Remarks 1 Union bolt 1 2 Washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure...

Page 207: ...to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad kit 1 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston se...

Page 208: ...ING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 25 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc defle...

Page 209: ...the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Brake pad pin Screw plug Brake caliper 6 Check Brake fluid level Belo...

Page 210: ...ing b to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never...

Page 211: ...dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Brake caliper 1 temporarily Washers Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is...

Page 212: ...ean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 6 Check Brake fluid level Below the minimum level mark a Add the recommended bra...

Page 213: ...l brake components 1 Install Brake master cylinder kit EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Washers Brake hoses Union bolt WARNING EWA13530 Proper brake hose routing is essenti...

Page 214: ...Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 17 4 Check Brake fluid level Below the minimum level mark a Add...

Page 215: ...Front cowling Refer to GENERAL CHASSIS on page 4 1 Front brake master cylinder Refer to FRONT BRAKE on page 4 31 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on p...

Page 216: ...lt 2 Loosen 13 Handlebar bolt 2 Loosen 14 Upper bracket pinch bolt 2 Loosen 15 Steering stem nut 1 16 Main switch coupler 2 Disconnect 17 Immobilizer unit coupler 1 Disconnect 18 Hazard switch coupler...

Page 217: ...Left handlebar 1 Right handlebar 2 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22900 INSTALLING THE HANDLEBARS 1 St...

Page 218: ...een left handlebar switch and clutch lever holder 7 Install Handlebar grip Grip end a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of...

Page 219: ...HANDLEBARS 4 60 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 34 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in...

Page 220: ...front fork legs Side cowling Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 17 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4...

Page 221: ...emove Q ty Remarks The following procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Nut 1 5 Spacer 1 6 Upper spring seat 1 7 Fork spring 1 8 Lower spring seat 1 9 Ou...

Page 222: ...front fork legs Order Job Parts to remove Q ty Remarks 14 Damper rod assembly 1 15 Damper adjusting rod 1 16 Damper adjusting valve 1 17 Damper adjusting valve spring 1 18 Inner tube 1 For installati...

Page 223: ...age 4 31 Front wheel Refer to FRONT WHEEL on page 4 17 Side cowlings Refer to GENERAL CHASSIS on page 4 1 3 Loosen Handlebar pinch bolt 1 Upper bracket pinch bolts 2 Handlebar bolt 3 Cap bolt 4 Lower...

Page 224: ...bolt e Remove the rod holder and fork spring compressor f Remove the nut and spacer 3 Drain Fork oil TIP Stroke the damper rod 1 several times while draining the fork oil 4 Remove Dust seal Oil seal...

Page 225: ...and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check Cap bolt 1 Cap bolt collar projections 2 Cracks damage Replace EAS14B1008 ASSEMBLING THE FRONT FORK...

Page 226: ...cate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil 5 Install Outer tube to the inner tube 6 Install Washer Oil seal 1 with the fork seal driver 2...

Page 227: ...er the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly because the f...

Page 228: ...seat c Install the fork spring TIP Install the spring with the smaller diameter a facing up A d Install the upper spring seat e Install the spacer f Install the nut g Reinstall the rod puller attachm...

Page 229: ...6 in or less o Remove the rod holder and fork spring compressor 16 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after...

Page 230: ...er to CABLE ROUTING on page 2 49 5 Install Plastic band 1 TIP Fasten the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression d...

Page 231: ...sor Refer to FRONT WHEEL on page 4 17 Front fork legs Refer to FRONT FORK on page 4 61 Handlebars Refer to HANDLEBARS on page 4 56 1 Horn lead connector 2 Disconnect 2 Horn 1 3 Front brake hose joint...

Page 232: ...r ring nut 1 14 Lower bracket 1 15 Upper bearing cover 1 16 Upper bearing inner race 1 17 Upper bearing 1 18 Lower bearing 1 19 Lower bearing inner race 1 20 Lower bearing dust seal 1 21 Upper bearing...

Page 233: ...arings Bearing races a Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Instal...

Page 234: ...RS on page 4 56 TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 70 TIP Temporarily tighten the upper and lower bracket pinch b...

Page 235: ...Passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Muffler Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm collar 1 2 Connecting arm 1 3 Relay arm collar...

Page 236: ...e the gas pressure drill a 2 0 3 0 mm 0 08 0 12 in hole through the rear shock absorber at a point 40 mm 1 57 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from r...

Page 237: ...l Bearing 1 Oil seals 2 to the relay arm Relay arm 3 Connecting arm 4 TIP When installing the oil seals to the relay arm or connecting arm face the character stamp of the oil seals outside EAS23310 IN...

Page 238: ...P When installing the connecting arm lift up the swingarm 5 Tighten Connecting arm and swingarm nut Rear shock absorber assembly bracket and frame nut 92 Nm 9 2 m kgf 66 ft lbf Rear shock absorber ass...

Page 239: ...25 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 76 1 Drive chain guard 1 2 Rear fender 1 3 Left footrest 1 4 Drive chain guide 1 5 Brake hose holder 1 6 Pivot shaft nu...

Page 240: ...SWINGARM 4 81 Removing the swingarm Order Job Parts to remove Q ty Remarks 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Bearing 2 For installation reverse the removal proce dure...

Page 241: ...e play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacer bearings collar and dust cover d Check the swingarm vertical movement B by movin...

Page 242: ...t 3 Wash Pivot shaft Dust cover Spacer Washers Bearings 4 Check Dust cover 1 Spacer 2 Collar 3 Bearings 4 Damage wear Replace EAS14B1011 INSTALLING THE SWINGARM 1 Lubricate Bearings Dust cover Pivot s...

Page 243: ...E DRIVE CHAIN SLACK on page 3 21 5 Dust cover 6 Collar 7 Swingarm 8 Pivot shaft A Left side B Right side Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut...

Page 244: ...emarks Drive chain Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Shift pedal 1 5 Drive sprocket cover 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive chai...

Page 245: ...ket as a set TIP While measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check Drive chain Stiffness Clea...

Page 246: ...eeth Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 29 EAS23480 CHECKING THE REAR WHEEL DRIVE HU...

Page 247: ...a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 ECA13550 A dri...

Page 248: ...CHAIN DRIVE 4 89...

Page 249: ...NG THE CYLINDER HEAD 5 25 INSTALLING THE CYLINDER HEAD 5 25 VALVES AND VALVE SPRINGS 5 27 REMOVING THE VALVES 5 29 CHECKING THE VALVES AND VALVE GUIDES 5 30 CHECKING THE VALVE SEATS 5 31 CHECKING THE...

Page 250: ...Y DRIVEN GEAR 5 65 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 65 INSTALLING THE CLUTCH 5 65 SHIFT SHAFT 5 68 CHECKING THE SHIFT SHAFT 5 69 CHECKING THE STOPPER LEVER 5 69 INSTALLING THE SHIFT SHAFT...

Page 251: ...5 91 REMOVING THE TRANSMISSION 5 95 CHECKING THE SHIFT FORKS 5 95 CHECKING THE SHIFT DRUM ASSEMBLY 5 96 CHECKING THE TRANSMISSION 5 96 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 97 INSTALLING THE TRANS...

Page 252: ...ure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compres sion gauge stabilizes W...

Page 253: ...allation reverse the removal proce dure Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Replace Same as without oil Pisto...

Page 254: ...n page 4 1 Side cowling Refer to GENERAL CHASSIS on page 4 1 Rear brake master cylinder Refer to REAR BRAKE on page 4 44 Radiator lower bracket Refer to RADIATOR on page 6 1 1 Left muffler cover 1 2 L...

Page 255: ...ht muffler clamp 1 Loosen 13 Right muffler 1 14 Right muffler gasket 1 15 Rear brake light switch coupler 1 Disconnect 16 Right footrest assembly 1 17 Exhaust chamber cover 1 18 Rear brake light switc...

Page 256: ...Parts to remove Q ty Remarks 25 Exhaust chamber protector 1 26 Exhaust chamber pipe protector clamp 1 Loosen 27 Exhaust chamber pipe protector 1 28 Exhaust chamber bracket 1 29 Exhaust pipe 1 30 Exha...

Page 257: ...ng Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 Radiator Refer to RADIATOR on page 6 1 Shif...

Page 258: ...to remove Q ty Remarks 5 Rear speed sensor lead coupler 1 Disconnect 6 Oil level switch lead coupler 1 Disconnect 7 Gear position sensor coupler 2 Disconnect 8 Engine ground lead 2 Disconnect 9 Clutc...

Page 259: ...ht inner panel bracket 1 5 Sidestand assembly 1 6 Sidestand switch 1 7 Holder 1 8 Sidestand switch bracket 1 9 Engine mounting bolt front right side 1 10 Engine mount collar front right side 2 11 Engi...

Page 260: ...r Job Parts to remove Q ty Remarks 16 Engine mount nut rear lower side 1 17 Engine mount bolt rear upper side 1 18 Engine mount bolt rear lower side 1 19 Engine 1 20 Engine mount adjusting bolt 2 For...

Page 261: ...ogether with damper 2 Engine mounting bolt front left side 3 temporary tighten TIP When installing the engine mount collar front left side set the damper toward the engine 5 Install Engine mount colla...

Page 262: ...t footrest assembly Refer to ADJUSTING THE RIDER FOOTRESTS on page 4 15 2 Install Muffler gasket 1 to muffler Muffler TIP When installing the muffler gasket set the surface a with the carbon to the ba...

Page 263: ...ENGINE REMOVAL 5 12 Installed depth of gasket c 3 5 mm 0 14 in...

Page 264: ...1 Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 21 Throttle body Refer to THROTTLE BODIES on page 7 12 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 1 Ignition coil co...

Page 265: ...5 36 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 3 4 Exhaust camshaft cap 3 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust cams...

Page 266: ...CAMSHAFTS 5 15 Removing the camshafts Order Job Parts to remove Q ty Remarks 14 Crankshaft sprocket 1 15 Collar 1 16 Straight key 1 For installation reverse the removal proce dure...

Page 267: ...TIP You can check that the 1 piston is at BTDC 105 by checking to see that the intake cam shaft sprocket timing mark c and exhaust camshaft sprocket timing mark d are aligned with the cylinder head s...

Page 268: ...place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft 3 Measure Camshaft runout Out of specification Replace Camshaft lobe dimension limit Intake A 3...

Page 269: ...the camshaft caps and then mea sure the width of the Plastigauge 2 5 Measure Camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylin der head and...

Page 270: ...he timing chain tensioner rod mount clip 5 into groove 6 and lock the timing chain tensioner rod c Push the timing chain tensioner rod in direction c d Make sure that the timing chain tensioner rod ca...

Page 271: ...at BTDC 105 align the K mark a with the crankcase mating surface b 5 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 ECA14B1012 Be sure to tighten the camshaft sprocket bolts to the spe...

Page 272: ...side camshaft cap mark Make sure the arrow mark a on each cam shaft points towards the right side of the engine When installing the camshaft cap face the hole with the screw thread b on the cam shaft...

Page 273: ...ming mark c Make sure the punch mark c on the camshaft sprocket is aligned with the cyl inder head mating surface d Out of alignment Adjust Refer to the installation steps above 12 Measure Valve clear...

Page 274: ...CAMSHAFTS 5 23 Tighten the cylinder head cover bolts stages and in a crisscross pattern Yamaha bond No 1215 Three Bond No 1215 90890 85505...

Page 275: ...Removing the cylinder head Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 3 Intake camshaft Refer to CAMSHAFTS on page 5 13 Exhaust camshaft Refer to CAMSHAFTS on pag...

Page 276: ...Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder head a Place a straightedge 1 and a thickness gauge 2 a...

Page 277: ...lowing the tightening order loosen the nut one by one and then retighten it to the specific torque TIP Tighten the cylinder head nuts in the tightening sequence as shown and torque them in 3 stages 5...

Page 278: ...s Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 24 1 Intake valve lifter 8 2 Intake valve pad 8 3 Intake valve cotter 16 4 Intake valve spring retainer 8 5 Inta...

Page 279: ...ve Q ty Remarks 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve spring retainer 8 14 Exhaust valve spring 8 15 Exhaust valve 8 16 Exhaust valve stem seal 8...

Page 280: ...lve seat width Refer to CHECKING THE VALVE SEATS on page 5 31 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the val...

Page 281: ...valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the val...

Page 282: ...the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification R...

Page 283: ...d Always replace lapped valves with new valves TIP When replacing the intake valves replace the intake valves without lapping the valve seats and valve faces When replacing the cylinder head or intake...

Page 284: ...dth c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valv...

Page 285: ...rr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retain...

Page 286: ...the valve tip with a soft face hammer ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad V...

Page 287: ...case Refer to AIR FILTER CASE on page 7 5 Side cowling Refer to GENERAL CHASSIS on page 4 1 Stator coil lead coupler Refer to GENERAL CHASSIS on page 4 1 1 Generator cover 1 2 Generator cover gasket...

Page 288: ...Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 3 Tighten Genera...

Page 289: ...GENERATOR 5 38 4 Apply Sealant onto the stator coil lead grommet 1 Yamaha bond No 1215 Three Bond No 1215 90890 85505...

Page 290: ...ing the starter clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 58 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch assembly 1 4 Starter idle gear 1...

Page 291: ...g surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the clutch housing assembly 2 and hold the clutch housing assem...

Page 292: ...ing the clutch housing assembly 1 with the sheave holder 2 tighten the starter clutch holder bolt 3 Fix the flat surface of the clutch housing assembly with the sheave holder Sheave holder 90890 01701...

Page 293: ...7 1 Generator cover Refer to GENERATOR on page 5 36 Air filter case Refer to AIR FILTER CASE on page 7 5 1 Pickup rotor cover 1 1 2 O ring 1 3 Crankshaft position sensor coupler 1 Disconnect 4 Pickup...

Page 294: ...the pickup rotor align the straight key a with the groove b on the pickup rotor Face the K mark on the pickup rotor outer side of the vehicle and install 2 Tighten Pickup rotor bolt 1 TIP While holdin...

Page 295: ...PICKUP ROTOR 5 44 Yamaha bond No 1215 Three Bond No 1215 90890 85505...

Page 296: ...Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 12 Engine outlet pi...

Page 297: ...motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 Gasket 2 8 Brush holder 1 9 O ring 1 10 Rear cover 1...

Page 298: ...asure Armature assembly resistances commu tator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the digital circuit tester b If any resi...

Page 299: ...ove portion at the side of the brush b Insert the armature assembly 3 into the brush holder 4 and push the brush 5 inside until it touches the armature assem bly 2 Install Rear cover 1 TIP Align the t...

Page 300: ...ELECTRIC STARTER 5 49 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers...

Page 301: ...ING THE ENGINE OIL on page 3 29 Fuel tank Refer to FUEL TANK on page 7 1 Coolant reservoir Refer to RADIATOR on page 6 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Clutch assembly Refer to CLUTC...

Page 302: ...8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 1 11 Relief valve assembly 1 12 Oil water pump assembly drive chain guide 1 13 Collar 1 14 Oil water pump assembly drive sprocket 1 15 Washer 1 16...

Page 303: ...Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Circlip 1 3 Oil pump housing 1 4 Bearing 1 5 Dowel pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For inst...

Page 304: ...assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Cracks damage wear Replace Oil pump housing 2 Cracks damage wear Replace the oil water pump assembly 2 M...

Page 305: ...ge wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 1 Oil pipe 2 Damage Replace O...

Page 306: ...mp side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 53 EAS25030 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install O ring onto the lower crankcase Oil water pump assembly 1 Dowel...

Page 307: ...ly 1 O ring Oil strainer 2 O ring Oil pipe 3 O rings Drain pipe 4 O rings EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Oil pan gasket Oil pan Oil level switch lead holder Oil level switch O ri...

Page 308: ...rain bolt Gasket TIP Tighten the oil pan bolts in stages and in a crisscross pattern Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil level switch bolt 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt 43 N...

Page 309: ...clutch cover Order Job Parts to remove Q ty Remarks Engine oil Drain 1 Pull lever cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 3 6 Oil filler cap 1 For ins...

Page 310: ...pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse...

Page 311: ...sion spring 6 2 Pressure plate 1 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 1 1 11 Clutch boss nut...

Page 312: ...CLUTCH 5 61 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Clutch housing assembly 1 18 Bearing 1 19 Washer 1 For installation reverse the removal proce dure...

Page 313: ...ned remove them 2 Remove Compression spring bolts 1 Compression springs Pressure plate 1 2 Pull rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate...

Page 314: ...Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure assem...

Page 315: ...s as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr th...

Page 316: ...ARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crank shaft as a set EAS252...

Page 317: ...tch boss nut at a cutout a in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates TIP First install a friction plate and then...

Page 318: ...E to the threads of only the clutch cover bolts b shown in the illustration Tighten the clutch cover bolts in stages and in a crisscross pattern 9 Install Pull lever spring 1 Pull lever 2 Washer Circl...

Page 319: ...HAIN DRIVE on page 4 85 Clutch assembly Refer to CLUTCH on page 5 58 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 S...

Page 320: ...AS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Lubricate the oil seal lips with lithium soap based grease Hook the end of the...

Page 321: ...ge 5 24 Starter motor Refer to ELECTRIC STARTER on page 5 45 Stator coil assembly Refer to GENERATOR on page 5 36 Pickup rotor Refer to PICKUP ROTOR on page 5 42 Clutch housing assembly Refer to CLUTC...

Page 322: ...orque Separating the crankcase Order Job Parts to remove Q ty Remarks 8 Crankcase breather cover 1 9 Crankcase breather cover gasket 1 10 Crankcase breather case 1 11 Crankcase breather case gasket 1...

Page 323: ...e crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with co...

Page 324: ...kcase bolts 1 10 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA14B1030 If the crankcase bolt is tightened more than the specified an...

Page 325: ...Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 70 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4...

Page 326: ...drive the piston pin out TIP For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore a...

Page 327: ...replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measur...

Page 328: ...Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the pis ton Piston ring side clearance Top ring 0 03...

Page 329: ...end lower bear ing into the connecting rod cap TIP Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on th...

Page 330: ...d install these parts to the crankshaft with the big end bearing kept in the current condi tion TIP Do not move the connecting rod or crank shaft until the clearance measurement has been completed Mak...

Page 331: ...rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearing...

Page 332: ...ng rod bolts with new ones b Clean the connecting rod bolts and lubri cate the bolt threads and seats with molyb denum disulfide oil c After installing the big end bearing assem ble the connecting rod...

Page 333: ...ate Piston Piston rings Cylinder with the recommended lubricant 6 Offset Piston ring end gaps 7 Lubricate Crankshaft pins Connecting rod big end bearing inner sur face with the recommended lubricant 8...

Page 334: ...b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and bearing surface of the connect ing rod bolt and conn...

Page 335: ...loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to...

Page 336: ...ge 5 70 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 75 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft...

Page 337: ...rfaces Bearing surfaces Scratches wear Replace the crank shaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings ECA139...

Page 338: ...kshaft journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select...

Page 339: ...l bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing por tions of the crankcase b Place the upper crankcase upside d...

Page 340: ...shaft journal bearings 4 Select Balancer shaft journal bearings J1 J4 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine th...

Page 341: ...CER ASSEMBLY 1 Install Balancer journal upper bearings into the upper crankcase Balancer journal lower bearings into the lower crankcase TIP Align the projections a on the balancer jour nal bearings 1...

Page 342: ...nkcase Separate Refer to CRANKCASE on page 5 70 1 Drive axle assembly 1 2 Shift drum retainer 2 3 Spring 2 4 Shift fork guide bar 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum assembly 1 8 Shift fo...

Page 343: ...stall the gear with groove a facing to the toothed lock washer 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd 4th pinion gear 1 9...

Page 344: ...rts to remove Q ty Remarks 1 Circlip 1 2 Bearing 1 3 Washer 1 4 1st wheel gear 1 5 Collar 1 6 5th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Collar 1 11 Toothed lock washer 1 12 Toothed...

Page 345: ...embly Order Job Parts to remove Q ty Remarks 16 Circlip 1 17 6th wheel gear 1 18 Circlip 1 19 Washer 1 20 2nd wheel gear 1 21 Collar 1 22 Collar 1 23 Oil seal 1 24 Circlip 1 25 Bearing 1 26 Drive axle...

Page 346: ...ts until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 2 1 Bearings 2 EAS26260 CHECKING...

Page 347: ...Damage pitting Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Meas...

Page 348: ...spline in the axle 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with a...

Page 349: ...4 Install Shift fork R 1 Shift fork L 2 Shift fork guide bar Springs Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel...

Page 350: ...TRANSMISSION 5 99...

Page 351: ...6 5 CHECKING THE OIL COOLER 6 7 INSTALLING THE OIL COOLER 6 7 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 10 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 11 WATER PUMP 6 1...

Page 352: ...Side cowling Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 1 Radiator cap 1 2 Coolant reservoir hose 1 Disconnect 3 Radiator fan motor coupler 2 Disconn...

Page 353: ...Job Parts to remove Q ty Remarks 12 Radiator bracket 1 13 Radiator fan 2 14 Thermostat bypass hose 2 1 Disconnect 15 Thermostat bypass hose 3 1 16 Radiator inlet pipe 1 17 Radiator inlet hose 1 For in...

Page 354: ...adiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolan...

Page 355: ...3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING...

Page 356: ...ing Refer to GENERAL CHASSIS on page 4 1 Lower cowling Refer to GENERAL CHASSIS on page 4 1 ECU Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 Radiator R...

Page 357: ...OLER 6 6 Removing the oil cooler Order Job Parts to remove Q ty Remarks 8 Water jacket joint 1 9 O ring 1 10 Water pump outlet pipe 1 11 O ring 1 12 O ring 1 For installation reverse the removal proce...

Page 358: ...union bolt and apply lithium soap based grease to the O ring Make sure the O ring is positioned properly Make sure the projection a on the oil cooler touches the projection b on the crankcase 3 Fill...

Page 359: ...ge 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 12 1 Coolant reservoir cover 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose...

Page 360: ...ermostat Order Job Parts to remove Q ty Remarks 12 Thermostat bypass hose 2 1 13 Water pump bypass hose 1 14 Joint 1 15 Thermostat bypass hose 1 1 16 Engine outlet pipe 1 17 O ring 1 For installation...

Page 361: ...rmostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat housing cover 1 Thermostat housing 2 Cracks damage Replace 3 Check Thermostat hose...

Page 362: ...the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 3 Measure Radiator cap o...

Page 363: ...s Q ty Remarks Oil water pump assembly Refer to OIL PUMP on page 5 50 Oil pump rotor Refer to OIL PUMP on page 5 50 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5...

Page 364: ...ING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the oil water pump assembly EAS26560 ASSEMBLING THE WA...

Page 365: ...nd 4 ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing dr...

Page 366: ...WATER PUMP 6 15...

Page 367: ...LTER CASE SEAL 7 9 CHECKING THE INTAKE FUNNEL 7 9 INSTALLING THE INTAKE FUNNEL AND LOWER AIR FILTER CASE 7 9 CHECKING THE INTAKE FUNNEL OPERATION 7 9 INSTALLING THE SECONDARY INJECTORS 7 10 INSTALLING...

Page 368: ...ollar washer 2 2 2 4 Fuel tank breather hose 1 Disconnect 5 Fuel tank overflow hose 1 Disconnect 6 Fuel pump coupler 1 Disconnect 7 Fuel sender coupler 1 Disconnect 8 Fuel hose connector cover 1 9 Fue...

Page 369: ...FUEL TANK 7 2 Removing the fuel tank and fuel pump Order Job Parts to remove Q ty Remarks 15 Fuel pump bracket 1 16 Fuel pump 1 17 Fuel pump gasket 1 For installation reverse the removal proce dure...

Page 370: ...disconnect the hose with tools TIP To remove the fuel hose from the fuel pump press the two buttons 1 on the sides of the connector and then remove the hose Before removing the hoses place a few rags...

Page 371: ...talling the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed...

Page 372: ...oupler 1 Disconnect 3 Fuel hose secondary injector fuel rail side 1 Disconnect 4 Upper air filter case 1 5 Sub wire harness 1 6 Secondary injector holder 1 7 Secondary injector 4 8 Fuel rail 2 9 Secon...

Page 373: ...e air filter case and secondary injectors Order Job Parts to remove Q ty Remarks 15 Intake funnel servo motor rod assembly 1 16 Intake funnel assembly 1 17 Intake funnel servo motor 1 For installation...

Page 374: ...arrow shown press the two but tons 2 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed EAS14B1106 REMOVING TH...

Page 375: ...ir filter case duct EAS14B1077 REMOVING THE INTAKE FUNNEL ASSEM BLY 1 Remove Intake funnel servo motor rod assembly Intake funnel assembly Intake funnel servo motor ECA14B1045 Do not disassemble the i...

Page 376: ...from the upper position to the seating position by its own weight EAS14B1067 INSTALLING THE INTAKE FUNNEL AND LOWER AIR FILTER CASE 1 Install Intake funnel servo motor Intake funnel servo motor rod as...

Page 377: ...ecified torque 1 Install a new seal onto the end of each injector 2 Install the injectors 1 to the fuel rails 2 3 Install the secondary injector joint 3 mak ing sure to install them in the correct dir...

Page 378: ...e make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel...

Page 379: ...ition sensor coupler 1 Disconnect 3 Sub wire harness coupler 2 Disconnect 4 Intake air pressure sensor coupler 1 Disconnect Coupler marked B 5 Throttle servo motor coupler 1 Disconnect 6 Coolant tempe...

Page 380: ...Removing the throttle body assembly Order Job Parts to remove Q ty Remarks 14 Crankshaft position sensor coupler 1 Disconnect 15 Heat protector 1 16 Throttle body joint 2 For installation reverse the...

Page 381: ...ect 3 Primary injector coupler 3 1 Disconnect 4 Primary injector coupler 4 1 Disconnect 5 Sub wire harness 1 6 Intake air pressure sensor hose 5 7 Intake air pressure sensor 1 8 Fuel rail 2 9 Primary...

Page 382: ...Air filter case Throttle bodies 2 Remove Sub wire harness Primary injectors a Remove the fuel rail screws 1 as shown 3 Remove Fuel rails 1 Primary injector joint 2 EAS14B1110 CHECKING THE PRIMARY INJE...

Page 383: ...surface with the air filter case side facing up b Install the caps 895 14169 00 onto the hose fittings a c Push the lever in the direction shown in the illustration to hold the throttle valves in the...

Page 384: ...pinch the O rings when installing the injectors When installing the injector install it at the same position as the removed cylin der If an injector is subject to strong shocks or excessive force rep...

Page 385: ...e the fuel tank bolt and holdup the fuel tank b Disconnect the fuel hose 1 from the fuel tank WARNING EWA14B1001 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in...

Page 386: ...selected g Adjust the position of the throttle position sensor angle so that 12 21 can appear in the meter h After adjusting the throttle position sensor angle tighten the throttle position sensor scr...

Page 387: ...14 is selected g Adjust the position of the accelerator posi tion sensor angle so that 12 22 can appear in the meter h After adjusting the accelerator position sen sor angle tighten the accelerator po...

Page 388: ...AIR INDUCTION SYSTEM 7 21 EAS27040 AIR INDUCTION SYSTEM...

Page 389: ...AIR INDUCTION SYSTEM 7 22 1 Lower air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover...

Page 390: ...case duct 2 2 Atmospheric pressure sensor coupler 1 Disconnect 3 Air filter case duct 1 4 Atmospheric pressure sensor hose 1 Disconnect 5 Atmospheric pressure sensor 1 6 Air induction system solenoid...

Page 391: ...R INDUCTION SYSTEM 7 24 Removing the reed valves Order Job Parts to remove Q ty Remarks 1 Reed valve cover 2 2 Reed valve assembly 2 3 Reed valve plate 4 For installation reverse the removal proce dur...

Page 392: ...he ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However...

Page 393: ...M 1 Install Reed valves Reed valve stoppers Reed valve base 2 Install Reed valve plate TIP Align the projection a on the cylinder head cover 1 with the hole b in the reed valve plate Reed valve assemb...

Page 394: ...AIR INDUCTION SYSTEM 7 27...

Page 395: ...NG 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTI...

Page 396: ...HECKING THE HORN 8 140 CHECKING THE OIL LEVEL SWITCH 8 140 CHECKING THE FUEL SENDER 8 141 CHECKING THE REAR SPEED SENSOR 8 141 CHECKING THE RADIATOR FAN MOTOR 8 142 CHECKING THE COOLANT TEMPERATURE SE...

Page 397: ......

Page 398: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...

Page 399: ...8 Sidestand switch 21 Joint coupler 22 ECU engine control unit 23 Ignition coil 1 24 Ignition coil 2 25 Ignition coil 3 26 Ignition coil 4 27 Spark plug 44 Crankshaft position sensor 50 Lean angle sen...

Page 400: ...to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following condition...

Page 401: ...ery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Gear position sensor 12 Battery nega...

Page 402: ...battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKI...

Page 403: ...GEAR POSITION SENSOR on page 8 147 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 125 Replace the sidestand switch 12 Check the relay unit dio...

Page 404: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...

Page 405: ...nd 12 Starter relay 13 Starter motor 14 Relay unit 15 Starting circuit cut off relay 17 Gear position sensor 18 Sidestand switch 21 Joint coupler 69 Right handlebar switch 71 Engine stop switch 73 Sta...

Page 406: ...al position The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor...

Page 407: ...R IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch...

Page 408: ...charge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 138 Starter motor is OK Perform the elec tric starting system troubleshooting...

Page 409: ...GEAR POSITION SENSOR on page 8 147 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 125 Replace the sidestand switch 12 Check the clutch switch...

Page 410: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM...

Page 411: ...CHARGING SYSTEM 8 14 2 AC magneto 3 Rectifier regulator 4 Joint 5 Main fuse 9 Battery 10 Engine ground 74 Engine ground...

Page 412: ...CHECKING AND CHARGING THE BATTERY on page 8 129 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 139 Replace the stator...

Page 413: ...CHARGING SYSTEM 8 16...

Page 414: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM...

Page 415: ...ne control unit 52 Meter assembly 64 High beam indicator light 67 Meter light 74 Engine ground 77 Left handlebar switch 79 Pass switch 80 Dimmer switch 89 Headlight 90 Auxiliary light 91 License plate...

Page 416: ...ht ignition and turn signal light Refer to CHECKING THE FUSES on page 8 129 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 129 Clean the battery terminals...

Page 417: ...LIGHTING SYSTEM 8 20 NG OK 8 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting system s wiring Replace the ECU or meter assembly...

Page 418: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM...

Page 419: ...eter 60 Transmission gear display 63 Coolant temperature warning light 65 Left turn signal indicator light 66 Right turn signal indicator light 68 Oil level switch 69 Right handlebar switch 70 Front b...

Page 420: ...Refer to CHECKING THE FUSES on page 8 129 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 129 Clean the battery terminals Recharge or replace the battery 3...

Page 421: ...2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 125 Replace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21...

Page 422: ...he gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR on page 8 147 Replace the gear position sensor 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 135 Repl...

Page 423: ...Replace the meter assembly 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 142 Replace the coolant temperature sen sor 2 Check the entire signaling...

Page 424: ...cator light is set to come on and that the brightness level of the light is adjusted properly Refer to FEATURES on page 1 2 Replace the meter assembly 2 Check the entire signaling system s wiring Refe...

Page 425: ...SIGNALING SYSTEM 8 28...

Page 426: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM...

Page 427: ...ery 10 Engine ground 22 ECU engine control unit 43 Coolant temperature sensor 74 Engine ground 95 Left radiator fan motor 96 Right radiator fan motor 97 Left radiator fan motor fuse 98 Right radiator...

Page 428: ...heck the main switch Refer to CHECKING THE SWITCHES on page 8 125 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 142 Repla...

Page 429: ...COOLING SYSTEM 8 32...

Page 430: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM...

Page 431: ...34 Secondary injector 2 35 Secondary injector 3 36 Secondary injector 4 37 Front speed sensor 38 Accelerator position sensor 39 Throttle position sensor 40 Intake funnel servo motor 41 Throttle servo...

Page 432: ...LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when...

Page 433: ...light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified...

Page 434: ...on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation table If a malfunction is detected in the sensors or actuators...

Page 435: ...nostic mode The diagnostic code number d01 appears on the clock stopwatch LCD 6 Set the engine stop switch to 7 Select the diagnostic code number corresponding to the fault code number by pressing the...

Page 436: ...FUEL INJECTION SYSTEM 8 39 TIP If the engine stop switch is set to set it to and then set it to again 9 Turn the main switch to OFF to cancel the diagnostic mode...

Page 437: ...is hot Air tem perature approx 20 C 68 F Compare the actually mea sured intake air temperature with the meter display value D 06 Coolant temperature When engine is cold Dis plays temperature closer to...

Page 438: ...D 16 Front wheel vehicle speed pulses 0 999 Displays the cumulative value of the front wheel vehicle speed pulses Front wheel stops make sure that the indication value is constant Rotate the front wh...

Page 439: ...ory code display No history 00 History exists Fault codes 11 70 If more than one code number is detected the dis play alternates every two seconds to show all the detected code numbers When all code n...

Page 440: ...on checker D 31 Cylinder 2 ignition coil Actuates the cylinder 2 igni tion coil five times at one sec ond intervals Illuminates the engine trou ble warning light Check the spark five times Connect an...

Page 441: ...4 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the injector 4 five times ECA1KB8801 Disconnect the fuel pump coupler D 40 Secondary inj...

Page 442: ...rning light Check the operating sound of the air induction system solenoid five times D 50 Fuel pump relay Actuates the fuel pump relay five times at one second intervals Illuminates the engine trou b...

Page 443: ...oupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicate...

Page 444: ...ntenance job Sensor inspection proce dure 1 Connection of crankshaft position sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or loc...

Page 445: ...code indicated Recovered Fault code indicated Check the next step 5 Crankshaft position sensor malfunction Sensor inspection procedure Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 137 C...

Page 446: ...k the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the...

Page 447: ...r inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 146 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fau...

Page 448: ...pressure sen sor hose is damaged discon nected clogged twisted or bent Repair or replace the sensor hose Starting the engine and oper ating it at idle Fully close the throttle and check the fault rec...

Page 449: ...ction Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check t...

Page 450: ...pen or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 01 D 1...

Page 451: ...next step 7 ECU malfunction Replace the ECU Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Po...

Page 452: ...upler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the m...

Page 453: ...ed No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Symptom Open or short circuit of ECU input line Blue Yellow lead Fail s...

Page 454: ...e the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Intake air pressure sensor malfunct...

Page 455: ...fault code indicated Recovered Fault code indicated Check the next step 3 ECU malfunction Replace the ECU Fault code No 20 Symptom When the main switch is ON there is a big difference in voltage valu...

Page 456: ...n for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicate...

Page 457: ...sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness P...

Page 458: ...ion procedure Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENSOR on page 8 146 During cold starting A tem perature close to the ambient temperature is indicated Indication is incorrect Replace the i...

Page 459: ...securely or replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connectio...

Page 460: ...o CHECKING THE ATMOSPHERIC PRES SURE SENSOR on page 8 145 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the...

Page 461: ...indicated Recovered Fault code indicated Check the next step 3 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending we...

Page 462: ...job Sensor inspection proce dure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch...

Page 463: ...n coil five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the spark five times Connect an ignition checker Item components and probable cause Check...

Page 464: ...rcuit Replace the wire harness Orange Orange Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the...

Page 465: ...five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupl...

Page 466: ...short circuit Replace the wire harness Gray Red Gray Red Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicat...

Page 467: ...ark five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the co...

Page 468: ...Replace the wire harness Orange Green Orange Green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Che...

Page 469: ...five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupl...

Page 470: ...ort circuit Replace the wire harness Gray Green Gray Green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indic...

Page 471: ...Code No 33 If not ignited replace the defective ECU Fault code No 36 Symptom Ignition coil 4 primary lead malfunction Fail safe action Engine startup Possible depending on the number of failed cylin d...

Page 472: ...3 five times D 39 Actuator oper ation Actuates the primary injector 4 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the...

Page 473: ...gine startup Possible depending on the number of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 36 D 37 D 38 D 39 D 36 Actuator oper ati...

Page 474: ...ing code No D 36 D 37 D 38 D 39 D 36 Actuator oper ation Actuates the primary injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the oper...

Page 475: ...s at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 3 five times D 43 Actuator oper ation Actuates the secondary...

Page 476: ...failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times a...

Page 477: ...ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five tim...

Page 478: ...tic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method...

Page 479: ...n rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the...

Page 480: ...Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 41 Symptom Open or short circuit of lean angle sensor lead Fail safe action Engine startup Impossible Riding Im...

Page 481: ...display Gear position switch ON neutral OFF in gear Checking method Shift the transmission and clutch lever C Fail safe action Engine startup Possible Riding Possible Diagnostic monitoring code No D 2...

Page 482: ...harness Start the engine and check the connection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered F...

Page 483: ...ect or repair the coupler Start the engine and check the secure connection of the coupler Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated...

Page 484: ...Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of clutch switch coupler Check the connection of the coupler is secure Rem...

Page 485: ...the ECU or speedometer Fault code No 43 Symptom Incorrect voltage supplied to the fuel injector and fuel pump Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No D...

Page 486: ...ndicated Recovered Fault code indicated Check the next step 4 Fuel injection system relay malfunction Check in the diagnostic mode Code No 50 No operation sound of fuel injection system relay is heard...

Page 487: ...ndication Check number 2 02 indication Check number 3 03 indication Check number 4 04 indication Check number 5 2 01 is indicated in Diagnostic mode Code No 60 EEP ROM data error for adjustment of CO...

Page 488: ...is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 E...

Page 489: ...ain switch Red Red Between the main switch and ignition fuse Brown Blue Brown Blue Between the ignition fuse and ECU Red White Red White Start and idle the engine for approximately 5 seconds Then chec...

Page 490: ...pen D 15 Meter display Accelerator position sensor signal 2 10 24 fully closed position 95 109 fully opened position Checking method Check with throttle grip fully closed Check with throttle grip full...

Page 491: ...lt code indicated Recovered Fault code indicated Check the next step Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under c...

Page 492: ...of power supply line 0 V Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under cer...

Page 493: ...t code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe actio...

Page 494: ...ng Poor connection Connect it securely or replace the har ness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check...

Page 495: ...er Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Place the main switch...

Page 496: ...the next step 5 Steering damper solenoid malfunction Refer to CHECKING THE STEERING DAMPER SOLE NOID on page 8 147 Place the main switch to the ON position and check the fault code indication No fault...

Page 497: ...nnection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2...

Page 498: ...tops the engine after 20 minutes if it is left idling Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No Meter display Checking method Item components and probable...

Page 499: ...t step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or r...

Page 500: ...rness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness...

Page 501: ...f main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wir...

Page 502: ...tion of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace t...

Page 503: ...FUEL INJECTION SYSTEM 8 106...

Page 504: ...FUEL PUMP SYSTEM 8 107 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM...

Page 505: ...h 4 Joint 5 Main fuse 9 Battery 10 Engine ground 11 Fuel injection system fuse 14 Relay unit 16 Fuel pump relay 20 Fuel pump 22 ECU engine control unit 69 Right handlebar switch 71 Engine stop switch...

Page 506: ...heck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 129 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 1...

Page 507: ...FUEL PUMP SYSTEM 8 110 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 107 Properly connect or repair the fuel pump system s wiring Replace the ECU...

Page 508: ...IMMOBILIZER SYSTEM 8 111 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM...

Page 509: ...4 Joint 5 Main fuse 7 Backup fuse 8 Immobilizer unit 9 Battery 10 Engine ground 21 Joint coupler 22 ECU engine control unit 52 Meter assembly 53 Immobilizer system indicator light 59 Multi function me...

Page 510: ...gistered during production therefore re registering at purchase is not neces sary ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the...

Page 511: ...the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Standby mode To enable the immobiliz...

Page 512: ...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 acti vated When the key...

Page 513: ...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 I...

Page 514: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 129 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 125 Replace...

Page 515: ...con secutive attempts 2 Signal received from unregistered stan dard key 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILI...

Page 516: ...5 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Undefinition code is received Noise i...

Page 517: ...IMMOBILIZER SYSTEM 8 120...

Page 518: ...ELECTRICAL COMPONENTS 8 121 EAS27972 ELECTRICAL COMPONENTS...

Page 519: ...ition coil 6 Battery 7 Fuse box 8 Main fuse 9 Fuel injection system fuse 10 Starter relay 11 Rear brake light switch 12 Gear position sensor 13 Sidestand switch 14 O2 sensor 15 Rear speed sensor 16 Oi...

Page 520: ...ELECTRICAL COMPONENTS 8 123...

Page 521: ...5 Intake air pressure sensor 6 Intake funnel servo motor 7 Fuel pump 8 Relay unit 9 Lean angle sensor 10 Coolant temperature sensor 11 Crankshaft position sensor 12 Throttle servo motor 13 Throttle p...

Page 522: ...ELECTRICAL COMPONENTS 8 125 EAS27980 CHECKING THE SWITCHES...

Page 523: ...switch 4 Dimmer switch 5 Pass switch 6 Turn signal switch 7 Traction control system switch 8 Sidestand switch 9 Gear position sensor 10 Oil level switch 11 Hazard switch 12 Front brake light switch 1...

Page 524: ...and to the 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 o...

Page 525: ...ight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead ot...

Page 526: ...nal d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong am...

Page 527: ...onsiderably Therefore take special care when charging the bat tery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuri...

Page 528: ...e battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery ch...

Page 529: ...tery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage sh...

Page 530: ...ity with the pocket tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester 1 and bat tery 12 V to the relay terminal...

Page 531: ...rminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery...

Page 532: ...ain switch to ON c Measure the turn signal hazard relay out put voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace TIP The pocket tester or the analog...

Page 533: ...er 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 continuit...

Page 534: ...1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket t...

Page 535: ...ion Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 11 a Connect the positive battery terminal 1 and starter motor lead 2...

Page 536: ...tester AC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the rectifier regulator input volt age Stator coil resistance 0 112...

Page 537: ...rminals c Measure the horn resistance 2 Check Horn sound Faulty sound Replace EAS28190 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level swi...

Page 538: ...nd wire harness as shown b Connect the pocket tester DC 20 V to the test harness speed sensor 3P Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester prob...

Page 539: ...s shown c Measure the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 24 WARNING EWA14130 Handle the c...

Page 540: ...ion sensor a Connect the pocket tester 1 k to the throttle position sensor terminal as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor TIP When inst...

Page 541: ...he digital circuit tester to the throttle servo motor coupler c Measure the throttle servo motor resis tance EAS28370 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid r...

Page 542: ...ANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 2 Check Cylinder identification sensor output volt age Out of speci...

Page 543: ...age EAS28420 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the headlight assembly WARNING EWA14110 Handle the intake air temperature sensor with special care...

Page 544: ...cification Replace the steer ing damper assembly a Disconnect the steering damper lead cou pler from wire harness b Connect the pocket tester 1 to the steering damper lead coupler c Measure the steeri...

Page 545: ...nal a 1st position Continuity Positive tester probe White 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe Pink 3 Negative tester probe Sensor terminal c 3rd pos...

Page 546: ...ELECTRICAL COMPONENTS 8 149...

Page 547: ...LING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PE...

Page 548: ...uel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damage...

Page 549: ...drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Sh...

Page 550: ...maged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or dama...

Page 551: ...tifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal...

Page 552: ...signal indicator light 66 Right turn signal indicator light 67 Meter light 68 Oil level switch 69 Right handlebar switch 70 Front brake light switch 71 Engine stop switch 72 D Mode switch 73 Start swi...

Page 553: ......

Page 554: ......

Page 555: ...WIRING DIAGRAM YZF R1 B SCHEMA DE CABLAGE YZF R1 B SCHALTPLAN YZF R1 B SCHEMA ELETTRICO YZF R1 B DIAGRAMA DE CONEXIONES DE YZF R1 B...

Page 556: ...WIRING DIAGRAM YZF R1 B SCHEMA DE CABLAGE YZF R1 B SCHALTPLAN YZF R1 B SCHEMA ELETTRICO YZF R1 B DIAGRAMA DE CONEXIONES DE YZF R1 B...

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Yamaha YZF-R1(B) 2012, Service Manual

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