Yamaha YZF-R1(P) 2002 Service Manual Download Page 1

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Summary of Contents for YZF-R1(P) 2002

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Page 3: ...YZF R1P YZF R1PC SERVICEMANUAL LIT 11616 15 47 5PW 28197 10 ...

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Page 5: ...1 by Yamaha Motor Corporation U S A First edition December 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 15 47 ...

Page 6: ...to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and 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 NOTE _...

Page 7: ...page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disas...

Page 8: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap base grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following...

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Page 10: ...S GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 11: ... INSTRUMENT FUNCTION 1 20 IMPORTANT INFORMATION 1 23 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 23 REPLACEMENT PARTS 1 23 GASKETS OIL SEALS AND O RINGS 1 23 LOCK WASHERS PLATES AND COTTER PINS 1 24 BEARINGS AND OIL SEALS 1 24 CIRCLIPS 1 24 CHECKING THE CONNECTIONS 1 25 SPECIAL TOOLS 1 26 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 11 ELECTR...

Page 12: ...AMS 2 25 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 30 CABLE ROUTING 2 35 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 1 SEATS 3 3 FUEL TANK 3 4 REMOVING THE FUEL TANK 3 5 REMOVING THE FUEL PUMP 3 5 INSTALLING THE FUEL PUMP 3 6 INSTALLING THE FUEL HOSE 3 6 COWLINGS...

Page 13: ...KE 3 37 ADJUSTING THE REAR BRAKE 3 38 CHECKING THE BRAKE FLUID LEVEL 3 39 CHECKING THE FRONT AND REAR BRAKE PADS 3 40 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 40 CHECKING THE FRONT AND REAR BRAKE HOSES 3 41 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 41 ADJUSTING THE SHIFT PEDAL 3 43 ADJUSTING THE DRIVE CHAIN SLACK 3 43 LUBRICATING THE DRIVE CHAIN 3 45 CHECKING AND ADJUSTING THE STEERING HEAD 3 45 CHECKI...

Page 14: ... PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE MASTER CYLINDER 4 26 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 29 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 30 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 32 FRONT BRAKE CALIPERS 4 34 REAR BRAKE CALIPER 4 36 DISASSE...

Page 15: ...CK ABSORBER ASSEMBLY 4 68 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 68 SWINGARM AND DRIVE CHAIN 4 69 REMOVING THE SWINGARM 4 71 REMOVING THE DRIVE CHAIN 4 72 CHECKING THE SWINGARM 4 72 CHECKING THE DRIVE CHAIN 4 73 INSTALLING THE SWINGARM 4 75 CHAPTER 5 OVERHAULING THE ENGINE ENGINE 5 1 DRIVE SPROCKET 5 1 EXHAUST PIPE 5 2 LEADS AND HOSES 5 4 ENGINE 5 6 INSTALLING THE ENGINE 5 7 CAMSHAFT 5 8 CY...

Page 16: ...R 5 33 PICKUP COIL 5 36 REMOVING THE PICKUP COIL ROTOR 5 38 INSTALLING THE PICKUP COIL ROTOR 5 38 CLUTCH 5 40 CLUTCH COVER 5 40 PULL LEVER SHAFT 5 41 CLUTCH 5 42 REMOVING THE CLUTCH 5 44 CHECKING THE FRICTION PLATES 5 44 CHECKING THE CLUTCH PLATES 5 45 CHECKING THE CLUTCH HOUSING 5 45 CHECKING THE CLUTCH BOSS 5 45 CHECKING THE PRESSURE PLATE 5 46 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 46 CHE...

Page 17: ...ET AND CHAINS 5 61 ASSEMBLING THE CRANKCASE 5 62 CONNECTING RODS AND PISTONS 5 64 REMOVING THE CONNECTING RODS AND PISTONS 5 65 REMOVING THE CRANKSHAFT ASSEMBLY 5 66 CHECKING THE CYLINDER AND PISTONS 5 66 CHECKING THE PISTON RINGS 5 68 CHECKING THE PISTON PINS 5 69 CHECKING THE BIG END BEARINGS 5 69 INSTALLING THE CONNECTING ROD AND PISTON 5 72 CRANKSHAFT 5 76 CHECKING THE CRANKSHAFT 5 77 CHECKING...

Page 18: ...R PUMP 6 14 ASSEMBLING THE WATER PUMP 6 15 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7 1 WIRING DIAGRAM 7 2 ECU S SELF DIAGNOSTIC FUNCTION 7 3 SUBSTITUTE CHARACTERISTICS OPERATION CONTROL FAIL SAFE ACTION 7 4 FAIL SAFE ACTIONS TABLE 7 4 TROUBLESHOORING CHART 7 5 DIAGNOSTIC MODE 7 6 TROUBLESHOOTING DETAILS 7 12 THROTTLE BODIES 7 29 CHECKING THE INJECTOR 7 33 CHECKING THE THROTTLE BODY 7...

Page 19: ... OF THE BULB SOCKETS 8 7 CHECKING THE LEDs 8 7 IGNITION SYSTEM 8 8 CIRCUIT DIAGRAM 8 8 TROUBLESHOOTING 8 9 ELECTRIC STARTING SYSTEM 8 13 CIRCUIT DIAGRAM 8 13 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 14 TROUBLESHOOTING 8 15 STARTER MOTOR 8 18 CHECKING THE STARTER MOTOR 8 20 ASSEMBLING THE STARTER MOTOR 8 21 CHARGING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 LIGHTING SYSTEM 8 25 CIRCU...

Page 20: ... 2 INCORRECT ENGINE IDLING SPEED 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 ELECTRICAL SYSTEMS 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYS...

Page 21: ... SIGNALING SYSTEM 9 6 HEADLIGHT DOES NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT COME ON 9 6 TURN SIGNAL BLINKS SLOWLY 9 6 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 HORN DOES NOT SOUND 9 6 ...

Page 22: ...00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts MOTORCYCLE IDENTIFICATION 1 ...

Page 23: ...r fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditio...

Page 24: ...njection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position ...

Page 25: ... Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed ...

Page 26: ... are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection timing and ignition timing and then sends con trol commands to the respective output interface circuits D Output interface circuits The output interface circuits convert the control signals output by the CPU into actuating ...

Page 27: ...ction system relay when the lean angle cut off switch is oper ated 2 Operating the headlight illumination relay The ECU controls the headlight relay 2 in accordance with the engine speed as required by the daytime illumination specification 3 Operating the radiator fan motor in accordance with the coolant temperature The ECU controls the radiator fan motor relay ON OFF in accordance with the coola...

Page 28: ...e pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose becomes clogged This valve opens when the fuel pressure at the discharge outlet reaches between 440 640 kPa 4 4 6 4 kg cm2 62 6 91 0 psi and returns the...

Page 29: ...force An intake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the diaphragm opens allowing the fuel to return from the fuel outlet to the fuel tank via the fuel return hose As a result because the intake vacuum fluctuates in accordance with the changes in the operating con...

Page 30: ... the flange that is integrated with the plunger to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized...

Page 31: ...the ECU which calculates the position of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calcu lated data in order to determine the corresponding injection timing Based on the changes in the time intervals of the signals generated by the pickup coil the ECU calculates the ignition timing advance to suit the operating conditions The injection...

Page 32: ...haust side head cover When the exhaust camshaft rotates the sensor generates a signal and sends it to the ECU Based on this sig nal and the signal from the crankshaft position sensor the ECU then actuates the injector of the cyl inder that is currently in order to supply fuel 1 Cylinder identification sensor 2 Camshaft ...

Page 33: ...oving contact that moves in unison with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve 1 Moving contact 2 Resistor board 3 Spring È Output voltage É Idling output position Ê Mechanical stopper Ë Mechanical s...

Page 34: ...silicon diaphragm con verts the intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure Atmospheric pressure sensor The atmospheric pressure sensor is used for making compensations to the changes in the air density caused by the chan...

Page 35: ...ich are then input into the ECU 1 Connector 2 Terminal 3 Tube 4 Thermistor 5 Holder È Resistance kΩ É Temperature C F Intake temperature sensor The intake temperature sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures This sensor...

Page 36: ...ceeds 65 degrees according to the tilt of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the motorcycle has overturned and stops the delivery of fuel to the engine by turning OFF the fuel injection system relay that powers the fuel pump and the injectors Once the cut off switch is tripped the ECU mai...

Page 37: ...to the injectors Further more the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on the signals from these sensors Determining the basic injection duration The intake air volume determines the basic injection duration In order to operate the engine in an optional condition it is necessary to supply fuel at an air...

Page 38: ...ermines the final injection duration based on the operating condition of the engine Composition of final injection duration 1 Injection at start 1 2 After start enrichment 2 3 Warm up enrichment 3 4 Acceleration compensation 5 5 Fuel cut off Deceleration compensation 5 6 Basic injection duration 7 Voltage compensation duration È RPM É Injection duration Ê Cranking Ë Warm up Ì Idle Í Acceleration Î...

Page 39: ... engine speed by stopping the injection of fuel into two cylinders when the engine speed becomes greater than the specified value If the engine speed increases further this control stops the injection of fuel to all the cylinders Thus the over revving control effects fuel cut off control in two stages Compensation item Check item Sensor used Starting injection 1 Coolant temperature Coolant tempera...

Page 40: ...to an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion Through the joint effort of these control systems the exhaust gas is cleaned in a highly efficient manner without sacrificing engine performance Three way catalytic converter system diagram 1 Ignition coil 2 Injector 3 Intake temperature sensor 4 Throttle pos...

Page 41: ...pushing the SELECT button switches the display between the various tripmeter and odome ter modes in the following order F TRIP TRIP A TRIP B ODO F TRIP To reset a tripmeter select it by pushing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior m...

Page 42: ...re the SELECT button was last pushed will be applied In this mode the multi function display shows the current setting for each function except the engine speed indicator light activity function To adjust the display brightness 1 Turn the key to OFF 2 Push and hold the SELECT button 3 Turn the key to ON and then after five seconds release the SELECT button 4 Push the RESET button to select the des...

Page 43: ...t between 7 000 and 12 000 r min in increments of 500 r min Be sure to set the deactivation function to a higher engine speed than for the activation function otherwise the engine speed indicator light will remain 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 engine speed The control mode...

Page 44: ...e parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior ...

Page 45: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always re...

Page 46: ...d disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact...

Page 47: ...move the genera tor rotor YU 01235 Rotor holding tool This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt YU 01304 Piston pin puller This tool is used to remove the piston pins YU 01312 A Fuel level gauge This tool is used to measure the fuel level in the float chamber Radiator cap tester YU 24460 01 Adapter YU 33984 Radiator...

Page 48: ... the front fork legs YM 01442 Fork seal driver This tool is used to install the front fork s oil seal and dust seal YU 08030 Carburetor synchronizer This guide is used to synchronize the carburetors Compression gauge YU 33223 Adapter YU 33223 3 Compression gauge Compression gauge adapter These tools are used to measure engine compression Valve spring compressor YM 04019 Attachment YM 4108 YM 4114 ...

Page 49: ...over This tool is used to remove or install the valve guides 4 mm 0 16 in 90890 04112 4 5 mm 0 18 in YM 4117 Valve guide installer This tool is used to install the valve guides 4 mm 0 16 in 90890 04113 4 5 mm 0 18 in YM 4118 Valve guide reamer This tool is used to rebore the new valve guides YM 34487 Dynamic spark tester This tool is used to check the ignition system components ACC 11001 05 01 Qui...

Page 50: ... compressor This tool is used to compress the piston rings when installing the piston into the cylinder YM 03176 Fuel pressure adapter This tool is needed to measure fuel pressure YU 03153 Pressure gauge This tool used is to measure fuel pres sure 90890 03158 Carburetor angle driver This tool is used to turn the air screw when synchronizing the throttle bodies Tool No Tool name Function Illustrati...

Page 51: ...05 mm 27 8 in Overall height 1 105 mm 43 5 in Seat height 820 mm 32 3 in Wheelbase 1 395 mm 54 9 in Minimum ground clearance 140 mm 5 5 in Minimum turning radius 3 900 mm 153 5 in Weight Wet with oil and a full fuel tank 193 kg 426 lb USA Canada 194 kg 428 lb California Maximum load except motorcycle 202 kg 445 lb USA Canada 201 kg 443 lb California GENERAL SPECIFICATIONS ...

Page 52: ...aded gasoline only Fuel tank capacity Total including reserve 17 L 3 74 Imp gal 4 49 US gal Reserve only 3 3 L 0 73 Imp gal 0 87 US gal Engine oil Lubrication system Wet sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 5 C 40 F or higher È Yamalube 4 10W30 or SAE 10W30 type SE motor oil 15 C 60 F or below É Quantity Total amount 3 8 L 3 34 Imp qt 4 02 US qt Without oil filter c...

Page 53: ...g pressure 95 125 kPa 0 95 1 25 kg cm2 13 8 18 1 psi Radiator core Width 340 mm 13 4 in Height 295 8 mm 11 6 in Depth 27 mm 1 06 in Coolant reservoir Capacity 0 24 L 0 21 Imp qt 0 25 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 68 43 28 28 1 581 Max impeller shaft tilt 0 15 mm 0 0059 in Starting system type Electric starter Electric fuel injection Type INP 731 4...

Page 54: ...clearance 0 028 0 062 mm 0 0011 0 0024 in Intake camshaft lobe dimensions Measurement A 32 5 32 6 mm 1 2795 1 2835 in 32 4 mm 1 2756 in Measurement B 24 95 25 05 mm 0 9823 0 9862 in 24 85 mm 0 9783 in Exhaust camshaft lobe dimensions Measurement A 32 95 33 05 mm 1 2972 1 3012 in 32 85 mm 1 2933 in Measurement B 24 95 25 05 mm 0 9823 0 9862 in 24 85 mm 0 9783 in Max camshaft runout 0 03 mm 0 0012 i...

Page 55: ... 9 1 1 mm 0 0354 0 0433 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Valve margin thickness D Intake 0 5 0 9 mm 0 0197 0 0354 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 in Exhaust 4 465 4 480 mm 0 1758 0 1764 in 4 43 mm 0 1744 in Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in 4 05 mm 0 1594 in Exhaust 4 500 4 512 ...

Page 56: ...n 37 0 mm 1 46 in Exhaust 40 67 mm 1 60 in 38 6 mm 1 52 in Installed length valve closed Intake 34 5 mm 1 36 in Exhaust 35 mm 1 38 in Compressed spring force installed Intake 82 96 N 8 2 9 6 kg 18 43 21 58 lb Exhaust 110 126 N 11 0 12 6 kg 24 73 28 32 lb Spring tilt Intake 2 5 1 7 mm 0 067 in Exhaust 2 5 1 8 mm 0 071 in Winding direction top view Intake Clockwise Exhaust Clockwise Item Standard Li...

Page 57: ... in Height H 5 mm 0 2 in Piston pin bore in the piston Diameter 17 002 17 013 mm 0 6694 0 6698 in 17 043 mm 0 6710 in Offset 0 5 mm 0 02 in Offset direction Intake side Piston pins Outside diameter 16 991 17 000 mm 0 6689 0 6693 in 16 971 mm 0 6681 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 00008 0 00087 in 0 072 mm 0 00283 in Piston rings Top ring Ring type Barrel Dimensions B T ...

Page 58: ...0 0138 in Connecting rods Crankshaft pin to big end bearing clearance 0 031 0 055 mm 0 0012 0 0022 in Bearing color code 1 Violet 0 White 1 Blue 2 Black Crankshaft Width A 52 40 57 25 mm 2 06 2 25 in Width B 300 75 302 65 mm 11 84 11 92 in Max runout C 0 03 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Crankshaft journal to crankshaft journal bearing clearance 0 029 0 053 m...

Page 59: ...1 mm 0 004 in Clutch springs Free length 6 5 mm 0 26 in Spring quantity 1 Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 68 43 1 581 Secondary reduction system Chain drive Secondary reduction ratio 43 16 2 688 Operation Left foot operation Gear ratios 1st gear 35 14 2 500 2nd gear 35 19 1 842 3rd gear 30 20 1 500 4th gear 28 21 1 333...

Page 60: ... 85 5 15 kΩ at 20 C 68 F Output voltage at idle Adjusted by tachometer Throttle bodies Model manufacturer quantity 40EIS MIKUNI 4 Intake vacuum pressure 25 3 kPa 190 mmHg 7 48 inHg Throttle cable free play at the flange of the throttle grip 3 5 mm ID mark 5PW1 00 USA Canada 5PW5 20 California Throttle value size 100 Max EXUP cable free play at the EXUP valve pulley 1 5 mm 0 059 in Item Standard Li...

Page 61: ... Max radial wheel runout 1 mm 0 04 in Max lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 ZR17 58W Model manufacturer Pilot SPORT E MICHELIN D208FL DUNLOP Tire pressure cold 0 90 kg 250 kPa 2 5 kgf cm2 36 3 psi 90 202 kg 250 kPa 2 5 kgf cm2 36 3 psi High speed riding 250 kPa 2 5 kgf cm2 36 3 psi Min tire tread depth 1 6 mm 0 06 in Rear tire Tire type Tubeless Size 190...

Page 62: ...e diameter 30 1 mm and 27 mm 1 19 in and 1 06 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket 38 42 mm 1 50 1 65 in Recommended fluid DOT 4 Brake pedal freeplay 4 3 9 3 mm 0 17 0 37 in Brake discs Diameter thickness 220 5 mm 8 66 0 20 in Min thickness 4 5 mm 0 18 in Max deflec...

Page 63: ...ending limit 0 2 mm 0 008 in Optional spring available No Fork oil Recommended oil Suspension oil 01 or equivalent Quantity each front fork leg 0 543 L 0 478 Imp qt 0 574 US qt Level from the top of the inner tube with the inner tube fully compressed and without the fork spring 88 mm 3 46 in Spring preload adjusting positions Minimum 8 Standard 6 Maximum 1 Rebound damping adjusting positions Minim...

Page 64: ...ilable No Standard spring preload gas air pressure 1 200 kPa 12 kg cm2 174 psi Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9 Rebound damping adjusting positions Minimum 20 Standard 15 Maximum 1 Compression damping adjusting positions Minimum 20 Standard 15 Maximum 1 from the fully turned in position Swingarm Free play at the end of the swingarm Radial 1 0 mm 0 04 in Axial 1 0 m...

Page 65: ...ator coil resistance color 0 19 0 23 Ω at 20 C 68 F W W Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH001 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 35 A Withstand voltage 200 V Battery Battery type GT12B 4 Battery voltage capacity 12 V 10 AH Specific gravity 1 320 Manufacturer GS Ten hour rate amperage 1 A Headlight type Halogen bulb...

Page 66: ... F Horn Horn type Plain Model manufacturer quantity YF 12 NIKKO 1 Max amperage 3 A Performance 105 113 db 2 m 6 6 ft Coil resistance 1 15 1 25 Ω at 20 C 68 F EXUP servo motor Type manufacturer 5PW YAMAHA Turn signal relay Relay type Full transistor Model manufacturer FE218BH DENSO Self cancelling device built in No Turn signal blinking frequency 75 95 cycles min Wattage 21 W 2 3 4 W Oil level gaug...

Page 67: ...s otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Tightening torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 ...

Page 68: ...haft sprocket Bolt M7 4 24 2 4 17 Water pump inlet pipe Bolt M6 1 10 1 0 7 2 LT Water pump outlet pipe Bolt M6 1 10 1 0 7 2 LT Oil water pump assembly driven sprocket Bolt M6 1 15 1 5 11 LT Oil pump Bolt M6 2 12 1 2 8 7 LT Oil cooler Bolt M20 1 35 3 5 25 E Engine oil drain bolt M14 1 43 4 3 31 Oil strainer housing Bolt M6 2 10 1 0 7 2 LT Oil water pump assembly driven sprocket cover Bolt M6 1 12 1...

Page 69: ...7 Pick up rotor cover Bolt M6 8 12 1 2 8 7 Shift shaft cover Bolt M6 5 12 1 2 8 7 Breather plate Bolt M6 5 10 1 0 7 2 LT Timing mark accessing screw Bolt M8 1 15 1 5 11 Starter clutch idle gear shaft Bolt M6 1 10 1 0 7 2 Starter one way clutch Bolt M6 3 12 1 2 8 7 LT Clutch boss Nut M20 1 105 10 5 76 Use a lock washer Clutch spring Bolt M6 6 8 0 8 5 8 Drive sprocket Nut M22 1 85 8 5 61 Use a lock ...

Page 70: ...r 32 Nm 3 2 m kg 23 ft lb with a torque wrench EXUP servo motor cover Screw M5 2 2 0 2 1 4 Intake air temperature sensor M12 1 18 1 8 13 Cylinder identification sensor Bolt M6 1 10 1 0 7 2 LT Atmospheric pressure sensor Screw M5 2 7 0 7 5 1 Speed sensor Bolt M6 1 10 1 0 7 2 Stator coil clamp Bolt M6 1 10 1 0 7 2 LT Crankcase tightening sequence Item Fastener Thread size Q ty Tightening torque Rema...

Page 71: ...nd inner panel M5 1 0 1 0 7 Grip end and handlebar M6 4 0 4 2 9 Brake hose holder and under bracket M6 7 0 7 5 1 Engine mounting Front mounting bolts M10 45 4 5 33 Rear mounting bolts upper and lower M10 50 5 0 36 Pinch bolts front M8 24 2 4 17 Engine mount adjust bolt rear M16 7 0 7 5 1 Exhaust pipe bracket and frame M8 34 3 4 25 Clutch cable adjuster lock nut engine side M8 7 0 7 5 1 Main frame ...

Page 72: ...pressure sensor and battery box M5 0 7 0 07 0 5 Lean angle cut off switch sensor and battery box M4 2 0 2 1 4 Rider footrest bracket and frame M8 28 2 8 20 Passenger footrest bracket and frame M8 28 2 8 20 Rear master cylinder M6 18 1 8 13 Rear brake hose union bolts M10 30 3 0 22 Sidestand M10 63 6 3 46 Front wheel axle and bolt M14 90 9 0 65 Rear wheel axle nut M24 150 15 0 108 Front brake calip...

Page 73: ...and outer E Oil pump housing E Oil strainer E Clutch pull rod LS Oil water pump drive sprocket and washer E Clutch thrust plate E Starter clutch idle gear inner surface E Starter clutch assembly E Primary driven gear E Transmission gears wheel and pinion M Main axle and drive axle M Shift drum E Shift forks and shift fork guide bars E Shift shaft E Shift shaft boss E Cylinder head cover mating sur...

Page 74: ...eel drive hub mating surface LS Rear brake pedal shaft LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivoting point and metal to metal moving parts LS Clutch lever pivoting point and metal to metal moving parts LS Relay arm connecting rod and rear shock absorber collar LS Pivot shaft LS Swing arm pivot bush LS Swing arm head pipe end and ...

Page 75: ...2 25 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator fan 2 Radiator 3 Water pump ...

Page 76: ...2 26 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint ...

Page 77: ...2 27 SPEC COOLING SYSTEM DIAGRAMS 1 Water pump 2 Radiator cap 3 Thermostat 4 Thermostat housing ...

Page 78: ...2 28 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator ...

Page 79: ...EC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake camshaft Piston cooler Main gallery Oil filter Oil cooler Relief valve Oil pump Strainer Main axle Mission cooler Drive axle ...

Page 80: ...2 30 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch ...

Page 81: ...2 31 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump ...

Page 82: ...2 32 SPEC LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe ...

Page 83: ...2 33 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

Page 84: ...2 34 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft ...

Page 85: ... the head light leads and position lamp leads at the place of white tape with the clamp behind the pawl of headlight body Í To turn signal light Î To main harness Ï Route the junction of the head light position lamp and turn signal light leads through the pawl on the headlight body Pay attention to the direction Ð Insert the headlight relay to the rib of the headlight body No special roder is spec...

Page 86: ...on 7 AC magneto lead 8 Speed sensor lead 9 lead 0 Rear brake switch lead A EXUP servo motor lead B AC magneto lead C AI system lead D Oil level switch lead E Sidestand switch lead F Wire harness assembly G Injector sub lead H Starter lead I lead J lead K Cover 1 L Injector sub lead M AI system lead N Oil level switch lead O Sidestand switch lead ...

Page 87: ...osition sensor lead under the throttle body Ñ Wiring section Ò Connect the leads behind the clamp without crankshaft position sensor lead Fasten the wire harness speed sensor neutral switch rear brake switch pick up coil and starter leads with the clamp inserted to the frame Ó EXUP servo motor Ô To rectifier regulator Õ Fasten the wire harness lead AC magneto lead and rectifier regulator lead junc...

Page 88: ...d through the clamp inserted to the box battery Clamp the lead as being in parallel along the fender Make sure to clamp three leads Fasten the wire harness with the clamp inserted to the hole of the box battery Routing position of each lead except the wire harness is not regulated in the clamp Branch from the main har ness Assembling point Beneath the under bracket below the cover steering Throttl...

Page 89: ...ead Press the lead of the coupler for ALARM in under the cou pler of ECU Pay attention not to allow the lead to slack and get caught after wiring when assembling the side cover Make sure to hook the har ness on the hook of battery box Pick up coil lead Should be wired in front of the clamp Neutral switch lead Should be wired in front of the clamp Fasten the lead junction lead by hooking on the paw...

Page 90: ...ide to the vehi cle outside Ì Fasten the clutch cable with the clamp to the inside of the coolant reservoir tank Í Fasten the sidestand switch lead behind the bracket and cut the tip Î To fuel tank Ï Pass the throttle cable in front of the brake hose Ð Pass the clutch cable behind the front fork Ñ Pass the handlebar switch lead and main switch lead between the steering stopper and front fork outer...

Page 91: ... behind of the throttle cable Ö Route the coolant temperature sensor lead between the engine and the radiator hose Route the clutch cable through the inside of radiator hose and fasten it with the clamp to the radiator Ø Fasten the clutch cable and coolant reservoir tank breather hose with the clamp ...

Page 92: ...hose G Oil level gauge lead H AI system hose I Sidestand switch lead J Fuel return hose K Fuel tank breather hose L Fuel feeder hose M Fuel tank drain hose N Injector sub lead O Wire harness P To throttle body Q To air cleaner R To fuel tank S Crankcase breather hose T Assembling point U Speed sensor lead V EXUP servo motor W EXUP servo motor lead X To throttle body Y Rear brake switch lead Z AC m...

Page 93: ... hose in the drive sprocket cover Î Do not pinch the hose Ï Pass the oil level gauge lead and sidestand switch lead by the inner side of the coolant hose Ð Route the fuel tank breather hose and fuel tank drain hoses through the clamp and pass by the outside of the bottom cowl ing Make the end length of hoses even Ñ Pass the fuel tank breather hose and fuel tank drain hose by the inner side of the ...

Page 94: ...ting direction of the relay Û Fasten the EXUP servo motor lead with the clamp inserted to the frame Ü Fasten the wire harness with the clamp inserted to the hole of battery box Point the tip of clamp upward Cut the tip according to the illustration Ý Fasten the EXUP servo motor lead with the clamp inserted to the frame Þ Clamp the oil level gauge and sidestand switch lead ß AI system hose Route by...

Page 95: ...EC for California 1 Canister 2 Roll over valve assembly 3 Hose fuel tank breather canister 4 Hose canister roll over valve 5 Hose roll over valve throttle body È To throttle body É To atomosphere CABLE ROUTING ...

Page 96: ... 3 30 Check for leakage Retighten if necessary Replace gasket s if necessary 6 Electronic fuel injection See page 3 14 Check and adjust engine idle speed and syn chronization 7 Evaporative emis sion control system for California only Check control system for damage Replace if necessary 8 Air induction sys tem See page 7 39 Check the air cut off valve reed valve and hose for damage Replace any dama...

Page 97: ... mi 25 000 km or 24 months Replace 9 Rear suspension link pivots See page 4 71 Check operation Correct if necessary 10 Shock absorber assembly See page 4 68 Check operation and for oil leakage Replace if necessary 11 Front fork See page 3 48 Check operation and for oil leakage Repair if necessary 12 Steering bearings See page 3 45 Check bearing assembly for looseness Moderately repack with lithium...

Page 98: ...SEATS EAS00039 SEATS T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the seats Remove the parts in the order listed 1 Passenger seat 1 2 Rider seat 1 For installation reverse the removal procedure ...

Page 99: ... Removing the fuel tank Remove the parts in the order listed Rider seat Refer to SEATS 1 Bolt 1 2 Bolt 1 3 Fuel sender coupler 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose connector cover 1 6 Fuel hose 1 7 Fuel return hose 1 8 Fuel tank overflow hose 1 9 Fuel tank breather hose 1 10 Fuel tank 1 For installation reverse the removal procedure ...

Page 100: ...e there may be fuel remain ing in it NOTE Before removing the hoses place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position REMOVING THE FUEL PUMP 1 Remove fuel pump CAUTION Do not drop the fuel pump or give it ...

Page 101: ...l pump as shown in the illustra tion Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose holders CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct posi tion otherwise the fuel hose will not be properly...

Page 102: ...the order listed Rider and passenger seats Refer to SEATS 1 Tail cowling 1 2 Bottom cowling 1 3 Front cowling inner panel left 1 4 Front cowling inner panel right 1 5 Left side cowling 1 6 Right side cowling 1 7 Windshield 1 8 Rear view mirror 2 9 Upper cowling 1 For installation reverse the removal procedure ...

Page 103: ... seat and fuel tank Refer to SEATS and FUEL TANK 1 Crankcase breather hose 1 2 Air filter case breather hose 1 3 Al system hose 1 4 Intake temperature sensor coupler 1 5 Clamp screw 4 Loosen 6 Bolt 1 7 Air filter case 1 8 Quick fastener 3 9 Ignition coil plate 2 10 Ignition coil coupler 4 Disconnect 11 Cylinder identification sensor coupler 1 12 Rubber baffle 1 For installation reverse the removal...

Page 104: ... or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case ignition coil plate Refer to AIR FILTER CASE bottom cowling side cowlings Refer to COWLINGS throttle body Refer to THROTTLE BODIES in chapter 7 radiator thermostat Refer to RADIATOR and THERMOSTAT in chapter 6 2 Remove spark plugs cylinder head...

Page 105: ... a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence È Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft clockwise as specified in the following table É Degrees that the crankshaft is turned counter clockwise Ê Cylinder Ë Combustion cycle Valv...

Page 106: ...to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are origi nally...

Page 107: ...ew valve pad number NOTE The new valve pad number is only an approxi mation The valve clearance must be mea sured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve pad with molybdenum disulfide grease Lubricate the valve lifter with molybdenum disulfide oil The valve lifter must turn smoo...

Page 108: ...3 1 27 230 235 240 1 28 1 32 235 240 1 33 1 37 240 Measured clearance INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 03 0 07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 08 0 12 120 125 130 135...

Page 109: ... valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 7 Install all removed parts NOTE For installation reverse the removal proce dure SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition ti...

Page 110: ... a With throttle body 3 as standard adjust throttle bodies 1 2 and 4 using the air screw 1 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION Do not use the throttle valve adjusting screws to adjust the throttle body sy...

Page 111: ...t 11 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY 12 Remove digital tachometer carburetor syncronizer 13 Remove fuel tank 14 Install fuel tank Refer to FUEL TANK rider seat Refer to SEATS Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE Prior to adjusting the engine idling speed the th...

Page 112: ...le free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE _ Prior to adjusting the throttle cable free play the engine idling speed should be adjusted properly 1 Check throttle cable free play a Out of specification Adjust Engine idling speed 1 000 1 100 r min Direction a Engine idling speed is increased Direction b Engine idling speed is dec...

Page 113: ...ator cable c Loosen the locknut 4 on the accelerator cable d Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained e Tighten the locknuts NOTE _ If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Direction a Throttle cable free play is increased Direction b Thro...

Page 114: ...ECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove rider seat Refer to SEATS fuel tank Refer to FUEL TANK air filter case ignition coil plates rubber baffle Refer to AIR FILTER CASE 2 Remove ignition coil spark plug CAUTION _ Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling i...

Page 115: ...Out of specification Regap 7 Install spark plug ignition coil NOTE _ Before installing the spark plug clean the spark plug and gasket surface 8 Install rubber baffle ignition coil plates air filter case Refer to AIR FILTER CASE fuel tank Refer to FUEL TANK rider seat Refer to SEATS Spark plug gap 0 8 0 9 mm 0 032 0 035 in T R 13 Nm 1 3 m kg 9 4 ft lb EAS00065 MEASURING THE COMPRESSION PRESSURE The...

Page 116: ...l tank Refer to FUEL TANK air filter case ignition coil plates rubber baffle Refer to AIR FILTER CASE 4 Remove spark plug ignition coil CAUTION _ Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 5 Install compression gauge 1 6 Measure compression pressure Out of specification Refer to steps ...

Page 117: ...he cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure at sea level Minimum 1 350 kPa 13 5 kg cm2 192 psi Standard 1 450 kPa 14 5 kg cm2 206 psi Maximum 1 500 kPa 15 0 k...

Page 118: ...a suitable stand Make sure the motorcycle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level NOTE _ Before checking the engine oil level wait a few minutes until the oil has ...

Page 119: ...lace a container under the engine oil drain bolt 3 Remove bottom cowling Refer to COWLINGS engine oil filler cap engine oil drain bolt 1 along with the gasket 4 Drain engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench YU 38411 b Lubricate the ...

Page 120: ...ecified amount of the recom mended engine oil 9 Install engine oil filler cap bottom cowling Refer to COWLINGS 10 Start the engine warm it up for several min utes and then turn it off 11 Check engine for engine oil leaks 12 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL Quantity Total amount 3 8 L 3 34 Imp qt 4 02 US qt Without oil filter cartridge replacement 2 9 L 2 55 Imp qt 3 07...

Page 121: ... not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PAN AND OIL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb EAS00079 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check clutch cable fr...

Page 122: ...ent procedure described below 3 Remove bottom cowling Refer to COWLINGS Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased 4 Adjust clutch mechanism Engine side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is obtained c Tighten the locknut d Check the clutch cable free play again and ad...

Page 123: ...uallu wet or dusty areas 4 Install air filter case cover CAUTION _ Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheat ing NOTE _ When installing the air filt...

Page 124: ...el hose 2 Cracks damage Replace Loose connection Connect properly NOTE Before removing the fuel hoses place a few rags in the area under where it will be removed 3 Install fuel tank Refer to FUEL TANK rider seat Refer to SEATS EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove rider seat Refer to SEATS fuel tank Refer to FUEL TANK 2 Check crankcase breather hose 1 Cracks damage Replace Loose c...

Page 125: ...gas leaks Replace 3 Check tightening torque NOTE Install the spring 0 with its longer part a positioned upward Upper part 2 of the EXUP cable is attached with the rubber boot cover Install the EXUP cable in parallel without twisting its upper and lower sides 4 Install radiator Refer to RADIATOR in chapter 6 T R Exhaust pipe nut 5 20 Nm 2 0 m kg 14 ft lb Exhaust pipe and exhaust valve pipe bolt 6 1...

Page 126: ...aximum EXUP cable free play at the EXUP valve pulley 1 5 mm 0 059 in 5 Adjust EXUP cable free play a Loosen both locknuts 1 b Insert a 4 mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover c Turn both adjusting bolts 2 counterclock wise until there is no EXUP cable free play d Turn both adjusting bolts 1 2 of a turn clock wise e Tighten both locknuts an...

Page 127: ...minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level CAUTION _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the...

Page 128: ...WLINGS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler 4 oil cooler inlet hose 5 oil cooler outlet hose 6 water jacket joint inlet hose 7 water pump inlet pipe 8 water pump outlet pipe 9 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install side cowlings bottom cowling Refer to COWLINGS ...

Page 129: ...ine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the hiss ing sound has stopped press down on the radiator cap and turn it counterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers ...

Page 130: ...on CAUTION _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different ...

Page 131: ... mum level mark a 13 Install coolant reservoir cap 14 Start the engine warm it up for several min utes and then stop it 15 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled 16 Install side cowling bottom cowling Refer to COWLINGS ...

Page 132: ...he arrow mark 2 on the brake lever holder WARNING _ A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce in loss of control and possi bly an accident Therefore check and if necessary bleed the brake system CAUTION _ After ...

Page 133: ...cknut 1 to specification WARNING _ A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake sys...

Page 134: ... may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid a...

Page 135: ...ake É Rear brake È É EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE _ The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear ...

Page 136: ...YDRAULIC BRAKE SYSTEM WARNING _ Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty NOTE _ Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before a...

Page 137: ...in position g Loosen the bleed screw NOTE _ Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to sp...

Page 138: ...he tightest point on the chain CAUTION _ A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the specified limits 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it falling over NOTE ...

Page 139: ..._ To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to specification e Tighten the wheel axle nut to specification CAUTION _ Do not loosen the wheel axle nut after tight ening it to the specified torque If the groove in the wheel axle nut is not aligned with the cotter pin hole in the wheel axle tighten the nut further until they are aligned Direction a Drive ...

Page 140: ...ly kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suit able for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the motorcycle on a level surface WARNING _ Securely support the mot...

Page 141: ...right angle to the steering nut wrench c Loosen the lower ring nut completely then tighten it to specification WARNING _ Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 Steering n...

Page 142: ...all of the cables and wires are prop erly routed T R 115 Nm 11 5 m kg 83 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 26 Nm 2 6 m kg 19 ft lb a Point the front wheel straight ahead b Install a plastic locking tie 1 loosely around the end of the handlebar as shown c Hook a spring gauge 2 onto the plastic locking tie d Hold the spring gauge at a 90 angle from the handlebar pul...

Page 143: ...nt fork Binding looseness Adjust the steering head EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it falling over 2 Check inner tube 1 Damage scratches Replace oil seal 2 Oil leakage Replace 3 Hold the motorcycle upright and apply the front brake 4 Check front fork operation Push down hard on the ha...

Page 144: ... Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION _ Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspe...

Page 145: ... Never go beyond the maximum or mini mum adjustment positions Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 26 clicks in direction b Standard 13 clicks in direction b Maximum 1 click in direction b with the adjusting screw fully turned in direction a 1 Adjust compression damping a Turn the adj...

Page 146: ...ion b with the adjusting screw fully turned in direction a EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING _ Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION _ Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload NOTE _ Adjust the spring preload with the special wrench and extension bar included in the ...

Page 147: ...nimum 1 Standard 4 Maximum 9 1 Adjust rebound damping a Turn the adjusting screw 1 in direction a or b Compression damping CAUTION _ Never go beyond the maximum or mini mum adjustment positions Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 20 clicks in direction b Standard 15 clicks in directi...

Page 148: ...r temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Direction a Compression damping is increased suspen sion is harder Direction b Compression damping is de...

Page 149: ...93 kg 426 lb For California 194 kg 428 lb Maximum load For USA Canada 202 kg 445 lb For California 201 kg 443 lb Cold tire pressure Front Rear Up to 90 kg 198 lb load 250 kPa 2 5 kgf cm2 36 3 psi 250 kPa 2 5 kgf cm2 36 3 psi 90 kg 198 lb maximum load 250 kPa 2 5 kgf cm2 36 3 psi 290 kPa 2 9 kgf cm2 42 1 psi High speed riding 250 kPa 2 5 kgf cm2 36 3 psi 250 kPa 2 5 kgf cm2 36 3 psi 2 Check tire su...

Page 150: ...g a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement È Tire É Wheel WARNING After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufac turer and of the same design No guarantee conce...

Page 151: ...mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Manufacturer Size Model DUNLOP 120 70ZR 17M C 58W D208FL MICHELIN 120 70ZR 17M C 58W Pilot SPORT E Manufacturer Size Model DUNLOP 190 50ZR 17M C 73W D208L MICHELIN 190 50ZR 17M C 73W Pilot SPORT EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage o...

Page 152: ... NOTE _ Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS00174 LUBRICATING THE REAR ...

Page 153: ... it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps beca...

Page 154: ...battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of the battery 20 30 Positive tes...

Page 155: ...y charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make 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 charger lead clip may generate heat in the contact area and a weak clip spri...

Page 156: ...tor the amperage for 3 5 minutes to check if the standard charging current is reached NO YES If the current does not exceed the standard charging current after 5 minutes replace the bat tery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current...

Page 157: ...harge the battery until the battery s charging voltage is 15 V Measure the battery open circuit volt age after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Voltage should be measured 30 ...

Page 158: ...s 10 Install rider seat Refer to SEATS EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove rider seat Refer to SEATS front cowling inner panel left Refer to COWLINGS 2 Check fuse a Connect the pocket tester to the fuse and check the continuity NOTE _ Set the p...

Page 159: ... than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install front cowling inner panel left Refer to COWLINGS rider seat Refer to SEATS Fuses Amperage rating Q ty Main 50 A 1 Fuel injection system 15 A 1 Headlight 20 A 1 Signaling ...

Page 160: ... and your hands away from the bulb until it has cooled down 4 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder CAUTION _ Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it wi...

Page 161: ...tically a Turn the adjusting screw 1 in direction a or b 2 Adjust headlight beam horizontally a Turn the adjusting screw 2 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is low ered Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left ...

Page 162: ... on a suitable stand so that the front wheel is elevated 1 Brake hose holder left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 4 Loosen 4 Wheel axle bolt 1 5 Front wheel axle 1 6 Front wheel 1 7 Collar left and right 2 8 Oil seal cover left and right 2 9 Brake disc left and right 2 For installation reverse the removal procedure FRONT WHEEL AND BRAKE DISCS 1 2 3 4 ...

Page 163: ...S EAS00518 FRONT WHEEL Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassembly procedure ...

Page 164: ...Remove left brake caliper right brake caliper NOTE Do not apply the brake lever when removing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent wheel axle 2 Check tire front wh...

Page 165: ...als a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE _ To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly CAUTION _ Do not contact the wheel bearing inner race 1 o...

Page 166: ... the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by on...

Page 167: ... with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Install the brake calipers by installing the bolts and then tightening them to the speci fied torque NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs 6 Install the brake hose holders by installing the bolts and...

Page 168: ... front brake push down hard on the handlebar several times to check for proper fork operation T R Wheel axle pinch bolt 18 Nm 1 8 m kg 13 ft lb T R Wheel axle pinch bolt 18 Nm 1 8 m kg 13 ft lb EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake discs i...

Page 169: ... the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE _ Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wh...

Page 170: ...e motorcycle on a suitable stand so that the rear wheel is elevated 1 Brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Wheel axle nut 2 5 Washer 1 6 Rear wheel axle 1 7 Left adjusting block 1 NOTE Make sure that the tapered side of the right adjusting block faces the wheel 8 Right adjusting block 1 9 Rear wheel 1 10 Brake caliper bracket 1 For installati...

Page 171: ... EAS00560 REAR WHEEL Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Spacer 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For installation reverse the disassembly procedure ...

Page 172: ... Job Part Q ty Remarks Remove the brake disc and rear wheel sprocket Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel sprocket 1 3 Collar left and right 2 4 Oil seal 1 5 Bearing 1 6 Rear wheel drive hub 1 7 Rear wheel drive hub damper 6 For installation reverse the removal procedure ...

Page 173: ...nger of it falling over NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove brake caliper 1 NOTE _ Do not depress the brake pedal when remov ing the brake caliper 3 Loosen locknut 1 adjusting bolt 2 4 Remove wheel axle nut 3 wheel axle rear wheel NOTE _ Push the rear wheel forward and remove the drive chain from the rear wheel sprocket ...

Page 174: ...bearings oil seals Refer to CHECKING THE FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure radial wheel runout lateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check rear wheel drive hub 1 Cracks damage Replace rear wheel drive hub dampers 2 Damage wear Replace ...

Page 175: ...r wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket NOTE _ Tighten the self locking nuts in stages and in a crisscross pattern T R Rear wheel sprocket self locking nut 100 Nm 10 m kg 72 ft lb EAS00571 INSTALLING THE REAR WHEEL 1 Lubrica...

Page 176: ... axle nut is not aligned with the cotter pin hole in the wheel axle tighten the nut further until they are aligned Drive chain slack 40 50 mm 1 57 1 97 in T R 150 Nm 15 m kg 108 ft lb T R 27 Nm 2 7 m kg 20 ft lb EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with th...

Page 177: ... 40 Nm 4 0 m kg 29 ft Ib Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Bleed screw 1 For installation reverse the removal procedure ...

Page 178: ...4 3 ft Ib T R 27 Nm 2 7 m kg 20 ft Ib Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake caliper 1 2 Brake pad 2 3 Brake pad shim 2 2 4 Brake pad spring 2 5 Bleed screw 1 For installation reverse the removal procedure ...

Page 179: ... Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00582 REPLACING THE...

Page 180: ...ds 1 along with the brake pad shims 4 Measure brake pad wear limit Out of specification Replace the brake pads as a set 5 Install brake pad shims onto the brake pads brake pads brake pad spring NOTE _ Always install new brake pads brake pad shims and a brake pad spring as a set Brake pad wear limit 0 5 mm 0 02 in ...

Page 181: ...ke pads and a new brake pad spring NOTE _ The arrow mark a on the brake pad spring must point in the direction of disc rotation 6 Install brake pad pins brake pad clips brake caliper T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R 40 Nm 4 0 m kg 29 ft lb 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL ...

Page 182: ...se or disas semble the brake caliper 1 Remove brake caliper 1 2 Remove brake pads 1 along with the brake pad shims 3 Measure brake pad wear limit Out of specification Replace the brake pads as a set 4 Install brake pad shims onto the brake pads brake pads NOTE _ Always install new brake pads and brake pad shims as a set Brake pad wear limit 0 8 mm 0 03 in ...

Page 183: ...e bleed screw d Install a new brake pad shim 3 onto each new brake pad 4 5 Install brake caliper T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R 27 Nm 2 7 m kg 20 ft lb 6 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake syst...

Page 184: ...linder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Circlip 1 8 Hose joint 1 9 Brake lever 1 10 Front brake switch connector 2 Disconnect 11 Union bolt 1 12 Copper washer 2 ...

Page 185: ... T R 30 Nm 3 0 m kg 22 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib Order Job Part Q ty Remarks 13 Brake hose 1 14 Brake master cylinder bracket 1 15 Brake master cylinder 1 16 Front brake switch 1 For installation reverse the removal procedure ...

Page 186: ...5 Order Job Part Q ty Remarks Disassembling the front brake master cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 187: ... the rear brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Hose joint 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 10 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 188: ... T R 16 Nm 1 6 m kg 12 ft Ib Order Job Part Q ty Remarks Disassembling the rear brake master cylinder Remove the parts in the order listed 1 Brake master cylinder kit 1 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 189: ...coupler 1 from the brake switch 2 Remove union bolt 2 copper washers 3 brake hoses 4 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and...

Page 190: ... scratches wear Replace brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air È Front É Rear È É 2 Check brake master cylinder kit Damage scratches wear Replace È Front É Rear È É 3 Check brake fluid reservoir 1 Cracks damage Replace brake fluid reservoir diaphragm 2 Cracks damage Replace È Front É Rear 4 Check brake hoses Cracks damage wear Replace É È ...

Page 191: ...k facing up Align the end of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt then the lower bolt 2 Install copper washers brake hose union bolt WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 NOTE _ While holding the brake hose tighten the union bolt as shown Turn the...

Page 192: ...er does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark...

Page 193: ... _ Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will s...

Page 194: ...d brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket 38 42 mm 1 50 1 65 in ...

Page 195: ... 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks Removing the front brake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure ...

Page 196: ... front brake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 197: ... 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 20 ft Ib Order Job Part Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure ...

Page 198: ...R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed 1 Brake caliper piston 2 2 Brake caliper piston seal 4 3 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 199: ...ke hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper WARNING _ Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Re...

Page 200: ...ke hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING _ Cover the brake caliper piston with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake c...

Page 201: ... Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly brake caliper body 3 Cracks damage Replace the brake cali per assembly brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING _ Whenever a brake caliper is disassembled replace the brake caliper ...

Page 202: ...er is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projecti...

Page 203: ...er does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark...

Page 204: ...ecommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper make sure that the brake pipe a touches the projection b on the brake caliper 2 Remove brake caliper 3 Inst...

Page 205: ...er does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark...

Page 206: ...rt Q ty Remarks Removing the front fork legs Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front cowling inner panels Refer to COWLINGS in chapter 3 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Handlebar pinch bolt 2 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal procedure ...

Page 207: ... Job Part Q ty Remarks Disassembling the front fork legs Remove the parts in the order listed 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Nut 1 5 Spring seat 1 6 Fork spring 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Dust seal 1 0 Oil seal clip 1 A Oil seal 1 B Washer 1 ...

Page 208: ... CHAS FRONT FORK T R 40 Nm 4 0 m kg 29 ft Ib Order Job Part Q ty Remarks C Damper rod assembly bolt 1 D Copper washer 1 E Damper rod assembly 1 F Inner tube 1 For assembly reverse the disassembly procedure ...

Page 209: ... is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 handlebar boss pinch bolt 3 lower bracket pinch bolt WARNING _ Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt 1 from the damper adjusting rod spacer 2 nut ...

Page 210: ...spring is compressed f Remove the spacer and nut Fork spring compressor YM 01441 Rod holder YM 01434 2 Remove dust seal oil seal clip 1 oil seal washer with a flat head screwdriver CAUTION Do not scratch the inner tube 3 Remove damper rod assembly bolt NOTE While holding the damper rod assembly with the damper rod holder 1 loosen the damper rod assembly bolt Damper rod holder YM 1423 ...

Page 211: ... length a Out of specification Replace Spring free length 246 mm 9 69 in 3 Check damper rod 1 Damage wear Replace obstruction Blow out all of the oil pas sages with compressed air CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling and assembling the front fork leg do ...

Page 212: ...embling the front fork leg make sure all of the components are clean 1 Install damper rod assembly 1 CAUTION _ Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate inner tube s outer surface 3 Tighten damper rod assembly bolt 1 LOCTITE NOTE _ While holding the damper rod assembl...

Page 213: ...icate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install oil seal 1 with the fork seal driver 2 Fork seal driver YM 01442 6 Install oil seal clip 1 NOTE _ Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install dust seal 1 with the fork ...

Page 214: ...l 10 Install nut 1 fork spring 2 spring seat 3 spacer 4 damper adjusting rod 5 cap bolt 6 a Remove the rod puller and adapter b Install the nut c Install the fork spring spring seat and spacer NOTE _ Install the spring with the smaller pitch a fac ing up È Quantity each front fork leg 0 543 L 0 478 Imp qt 0 574 US qt Recommended oil Suspension oil 01 or equiva lent Front fork leg oil level from th...

Page 215: ...t 1 and position it as specified b h Set the cap bolt distance c to specification i Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt j Hold the cap bolt and tighten the nut to specification k Remove the rod holder and fork spring com pressor WARNING The fork spring is compressed Always use a new cap bolt O ring Fork spring compressor YM 01441 Rod holder YM 01434 D...

Page 216: ...fork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt cap bolt 1 handlebar boss pinch bolt 2 upper bracket pinch bolt 3 WARNING _ Make sure the brake hoses are routed prop erly 3 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 T R 23 Nm 2 3 m kg 17 ft lb T R 23 Nm 2 3 m kg 17 ft lb T R 13 Nm 1 3 m kg...

Page 217: ... 1 3 m kg 9 4 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks Removing the handlebars Remove the parts in the order listed 1 Left grip end 1 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever 1 Disconnect 7 Right grip end 1 8 Throttle cable housing 1 9 Throttle cable 2 10 Throttle grip 1 ...

Page 218: ... 2 9 ft Ib Order Job Part Q ty Remarks 11 Front brake switch connector 2 Disconnect 12 Right handlebar switch 1 13 Brake master cylinder bracket 1 14 Brake master cylinder 1 15 Handlebar pinch bolt 4 16 Upper bracket bolt 2 17 Upper bracket pinch bolt 2 18 Steering stem nut 1 19 Upper bracket 1 20 Left handlebar 1 21 Right handlebar 1 For installation reverse the removal procedure ...

Page 219: ...grip off the handlebar 3 Remove throttle cable housing 1 throttle grip 2 NOTE _ While removing the throttle cable housing pull back the rubber cover 3 EAS00669 CHECKING THE HANDLEBARS 1 Check left handlebar 1 right handlebar 2 Bends cracks damage Replace WARNING _ Do not attempt to straighten bent handle bars as this may dangerously weaken them EAS00674 INSTALLING THE HANDLEBARS 1 Stand the motorc...

Page 220: ...wer bolt NOTE _ Align the mating surfaces of the brake mas ter cylinder holder with the punch mark a in the right handlebar There should be 2 mm of clearance between the right handlebar switch and the brake master cylinder holder 4 Install throttle grip throttle cable housing 1 throttle cables NOTE _ Align the projection a on the throttle cable housing with the hole b in the right handlebar 5 Inst...

Page 221: ...he left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 8 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 9 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 15...

Page 222: ...emarks Removing the lower bracket Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK 1 Main switch coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar assembly 1 5 Steering stem nut 1 6 Upper bracket 1 7 Lower bracket panel 1 8 Brake hose holder bolt 1 9 Lock washer 1 10 Upper ring nut 1 11...

Page 223: ... kg 83 ft lb T R 26 Nm 2 6 m kg 19 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib Order Job Part Q ty Remarks 12 Lower ring nut 1 13 Lower bracket 1 14 Bearing cover 1 15 Bearing inner race 2 16 Upper bearing 1 17 Lower bearing 1 18 Dust seal 1 19 Bearing outer race 2 For installation reverse the removal procedure ...

Page 224: ...e steering nut wrench 2 WARNING _ Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Steering nut wrench YU 33975 Recommended cleaning solvent Kerosene 2 Check bearings 1 bearing races 2 Damage pitting Replace 3 Replace bearings bearing races a Remove the bearing races 1 from the steering head pipe with a lo...

Page 225: ...eck upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races 2 Install lower ring nut 1 rubber washer 2 upper ring nut 3 lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 3 Install upper bracket steering stem nut NOTE _ Temporarily tighten the steering ...

Page 226: ...orber assembly Remove the parts in the order listed 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt spacer 1 1 1 4 Rear shock absorber assembly 1 5 Collar oil seal bearing 1 2 1 6 Self locking nut bolt 1 1 7 Relay arm 1 8 Collar oil seal bearing 1 2 2 9 Self locking nut bolt collar 1 1 1 10 Connecting arm 1 11 Collar oil seal bearing 2 4 2 For installation reverse t...

Page 227: ... or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND ...

Page 228: ... motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear shock absorber assembly lower bolt 1 relay arm to swingarm bolt 2 NOTE While removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly NOTE Raise the swingarm and then remove the rear shock absorb...

Page 229: ...seals Damage wear Replace bolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate spacers bearings 2 Install rear shock absorber assembly NOTE _ When installing the rear shock absorber assembly lift up the swingarm Install the connecting arm front bolt from the right 3 Tighten rear shock absorber assembly upper nut rear shock absorber assembly lower nut rel...

Page 230: ...9 ft Ib Order Job Part Q ty Remarks Removing the swingarm and drive chain Remove the parts in the order listed Rear wheel Refer to REAR WHEEL AND BRAKE DISC Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY Drive sprocket Refer to ENGINE in chapter 5 1 Adjusting bolt locknut 2 2 2 Drive chain guard 1 3 Rear fender 1 4 Brake hose holder 1 5 Pivot shaft nut washer 1 1 6 Pivot shaft 1 7 Swing...

Page 231: ...g 3 6 ft Ib T R 105 Nm 10 5 m kg 76 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks 8 Drive chain 1 9 Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Bearing 2 13 Pivot shaft adjust bolt 1 For installation reverse the removal procedure ...

Page 232: ...lt hold the swingarm so that it does not drop down 3 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play È by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement É by moving the sw...

Page 233: ... _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove drive chain with the drive chain cutter NOTE Only cut the drive chain if it or the swingarm is to be replaced EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent pivot s...

Page 234: ...s 3 oil seals 4 Damage pitting Replace 7 Check collars 5 Damage scratches Replace EAS00709 CHECKING THE DRIVE CHAIN 1 Measure ten link section a of the drive chain Out of specification Replace the drive chain NOTE _ While measuring the ten link section push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and A as shown Perform this measurement at tw...

Page 235: ...n High pressure meth ods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Don t soak drive chain in kerosine more them ten minutes O ring is damage by kerosine 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace ...

Page 236: ...Use the pivot shaft wrench 2 to tighten the pivot adjust bolt to specification torque 2 Install relay arm connecting arms NOTE _ Install the connecting arm front bolt 1 from the left 3 Install rear shock absorber assembly rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and INSTALL ING THE REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Pi...

Page 237: ... 2 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib Order Job Part Q ty Remarks Removing the drive sprocket Remove the parts in the order listed 1 Locknut 2 2 Shift rod 1 3 Drive sprocket cover 1 4 Lock washer 1 5 Drive sprocket 1 6 Shift arm 1 For installation reverse the removal procedure ENGINE ...

Page 238: ... pipe Remove the parts in the order listed Rider seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly Refer to RADIATOR in chapter 6 1 EXUP valve pulley cover 1 2 EXUP valve pulley 1 3 EXUP cable 2 4 EXUP valve linkage 1 5 Exhaust pipe assembly 1 6 Exha...

Page 239: ...g 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib Order Job Part Q ty Remarks 7 Exhaust valve pipe 1 8 Muffler 1 For installation reverse the removal procedure ...

Page 240: ...ilter case Refer to AIR FILTER CASE in chapter 3 Throttle body assembly Refer to THROTTLE BODIES in chapter 7 Engine oil and oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Oil cooler and thermostat assembly Refer to OIL COOLER and THERMOSTAT in chapter 6 1 Battery negative lead 1 CAUTION First disconnect the negative lead then the positive lead 2 Battery positive lead 1 ...

Page 241: ... 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect 6 Ground lead 1 Disconnect 7 Starter motor 1 8 Stator coil assembly coupler 1 Disconnect 9 Pickup coil coupler 1 Disconnect 10 Oil level switch connector 1 Disconnect 11 Neutral switch 1 12 Speed sensor 1 For connecting reverse the disconnection procedure ...

Page 242: ... R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine 1 Pinch bolt 2 Loosen 2 Right front mounting bolt 1 3 Washer 1 4 Spacer 1 5 Left front mounting bolt 2 6 Washer 2 7 Self locking nut 2 8 Rear mounting bolt 2 9 Engine mounting adjust bolt 2 For installation reverse the removal proc...

Page 243: ...ngine mounting adjust bolt 2 Tighten the bolts in the following order Pivot shaft wrench YM 01471 T R Engine mounting adjust bolt 1 7 Nm 0 7 m kg 5 1 ft lb Self locking nut 3 50 Nm 5 0 m kg 36 ft lb Left front mounting bolt 4 45 Nm 4 5 m kg 33 ft lb Right front mounting bolt 5 45 Nm 4 5 m kg 33 ft lb Pinch bolt 6 24 Nm 2 4 m kg 17 ft lb 3 Install shift arm 1 NOTE _ Align the punch mark a in the sh...

Page 244: ...inder head covers Remove the parts in the order listed Throttle body assembly Refer to THROTTLE BODIES in chap ter 7 Radiator assembly and thermostat assembly Refer to RADIATOR and THERMO STAT in chapter 6 1 Spark plug 4 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Timing chain guide top side 1 5 Cylinder identification sensor 1 For installation reverse the removal procedure ...

Page 245: ...he order listed Pickup coil rotor cover Refer to PICKUP COIL 1 Timing chain tensioner cap bolt 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Timing chain guide exhaust side 1 5 Intake camshaft sprocket 1 NOTE During removal the dowel pins may still be connected to the camshaft caps 6 Exhaust camshaft sprocket 1 7 Intake camshaft cap 3 8 Dowel pin 6 9 Exhaust camshaft cap 3 10 Do...

Page 246: ...2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib Order Job Part Q ty Remarks 13 Pin 1 14 Timing chain guide intake side 1 For installation reverse the removal procedure ...

Page 247: ...oke align the TDC mark a on the pickup coil rotor with the crankcase mating surface b NOTE _ TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Loosen camshaft sprocket bolts 1 3 Loosen cap bolt 1 4 Remove timing chain tensioner 2 gasket 5 Remove camshaft sprockets 1 NOTE _ To prevent the timing chain from falling into the crankcase fasten it with ...

Page 248: ...attern working from the outside in 7 Remove intake camshaft 1 exhaust camshaft 2 EAS00204 CHECKING THE CAMSHAFTS 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft 2 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 32 4 mm 1 2756 in b 24 85 mm 0 9783 in Exhaust camshaft a 32 85 mm 1 293...

Page 249: ...haft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps NOTE _ Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge ...

Page 250: ...DES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check timing chain 1 Damage stiffness Replace the timing chain and camshaft sprockets as a set 2 Check camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check timing chain guide exhau...

Page 251: ...t camshaft 1 intake camshaft 2 with the camshaft sprockets temporarily tightened NOTE _ Make sure the punch mark a faces up 2 Install dowel pins intake camshaft caps exhaust camshaft caps NOTE _ Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows I Intake E Exhaust Make sure the arrow mark a on each cam shaft cap points towards the right side...

Page 252: ... sprockets and then install the camshaft sprockets onto the camshafts NOTE _ When installing the camshaft sprockets start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side CAUTION _ Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing d Turn both camshafts opposite each other so that the punch mark a ...

Page 253: ...uld face UP WARNING _ Always use a new gasket c Tighten the timing chain tensioner bolts 3 to the specified torque d Remove the screwdriver mark sure that the timing chain tensioner rod releases and then tighten the cap bolt to the specified torque 7 Turn crankshaft several turns clockwise 8 Check TDC mark a Make sure the TDC mark a is aligned with the crankcase mating surface b T R Timing chain t...

Page 254: ...lts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Install timing chain guide top side 11 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 12 Install timing plate cover T R 24 Nm 2 4 m kg 17 ft lb ...

Page 255: ... 14 ft lb 2nd 121 or 50 Nm 5 0 m kg 36 ft lb T R 1st 20 Nm 2 0 m kg 14 ft lb T R 12 Nm 1 2 m kg 8 7 ft Ib Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE Intake and exhaust camshafts Refer to CAMSHAFTS 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal procedure ...

Page 256: ...avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on th...

Page 257: ...ately 20 Nm 2 0 m kg 14 ft lb with a torque wrench Retighten the nuts to specification torque NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 4 Install exhaust camshaft intake camshaft Refer to INSTALLING THE CAMSHAFTS New T R 20 Nm 2 0 m kg 14 ft lb T R 105 or 50 Nm 5 0 m kg 36 ft lb T R ...

Page 258: ...lve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve oil seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 ...

Page 259: ...e lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 For installation reverse the removal procedure ...

Page 260: ...reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE _ There should be no leakage at the valve seat 1 3 Remove valve cotters 1 NOTE _ Remove the valve cotters by compressing the va...

Page 261: ...and installation and to maintain the correct fit heat the cylinder head to 100 C in an oven a Remove the 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 valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE _ After replaci...

Page 262: ...116 Valve guide installer Intake 4 0 mm 0 16 in 90890 04112 Exhaust 4 5 mm 0 18 in YM 4117 Valve guide reamer Intake 4 0 mm 0 16 in 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 5 Measure valve margin thickness a Out of specification Replace the valve 6 Measure valve stem runout Out of specification Replace the valve NOTE _ When installing a new valve always replace the valve guide If the valve is re...

Page 263: ...ye Dykem 1 onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE _ Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap valve face valve seat NOTE _ After replacing the cylinder head or replacing the valve and valve...

Page 264: ...nd repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width a again If the valve seat width i...

Page 265: ...b at 35 mm 1 38 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake valve spring 1 7 mm 0 067 in Exhaust valve spring 1 8 mm 0 071 in EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00245 INSTALLING THE VALVES The ...

Page 266: ...e larger pitch a facing up b Smaller pitch NOTE Make sure that each valve is installed in its original place Refer to the following embossed marks Right and left intake valve s 4XV Middle intake valve s 4XV Exhaust valve s 5LV 4 Install valve cotters 1 NOTE _ Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach ment 3 V...

Page 267: ...r CAUTION _ Hitting the valve tip with excessive force could damage the valve 6 Install valve pad 1 valve lifter 2 NOTE _ Lubricate the valve lifter and valve pad with molybdenum disulfide oil The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 268: ... Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Generator rotor cover 1 2 Generator rotor cover gasket 1 3 Dowel pin 2 4 Generator rotor bolt 1 5 Generator rotor 1 6 Stator coil assembly coupler 1 Disconnect 7 Stator coil assembly lead holder 1 8 Stator coil assembly 1 For installation reverse...

Page 269: ...r NOTE While holding the generator rotor 2 with the rotor holding tool 3 loosen the generator rotor bolt 3 Remove generator rotor 1 with the flywheel puller 2 and rotor holding tool 3 Rotor holding tool YU 01235 Flywheel puller YM 01080 A INSTALLING THE GENERATOR 1 Apply sealant onto the stator coil assembly lead grom met 2 Install generator rotor washer generator rotor bolt WARNING Always use a n...

Page 270: ... the generator rotor bolt WARNING Replace the rotor bolt and washer with new ones Clean the rotor bolt NOTE The tightening procedure of rotor bolt is angle controlled therefore tighten the nuts using the following procedure a Tighten the connecting rod nuts to the spec ified torque b Tighten the rotor bolt further to reach the specified angle 60 Rotor holding tool YU 01235 T R Rotor bolt 1st 65 Nm...

Page 271: ... and per form the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagon bolt note that the angle from one corner to another is 60 4 Install generator rotor cover NOTE Tighten the generator rotor cover bolts in stages and in a crisscross pattern ...

Page 272: ... Remove the parts in the order listed Rider seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling and right side cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Generator rotor cover Refer to GENERATOR 1 Clutch cable 1 2 Clutch cable holder 1 3 Pickup coil lead holder 1 4 Pickup coil rotor cover 1 5 Pickup coil rotor cover...

Page 273: ...5 Nm 1 5 m kg 11 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 7 Crankshaft position sensor coupler 1 Disconnect 8 Crankshaft position sensor 1 9 Pickup coil rotor 1 For installation reverse the removal procedure ...

Page 274: ...re fully loosened remove them 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the rotor holding tool 4 loosen the pickup coil rotor bolt Rotor holding tool YU 01235 INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 washer pickup coil rotor bolt NOTE When installing the pickup coil rotor align the pin 2 in the crankshaft sprock...

Page 275: ...43 ft lb 3 Apply sealant onto the crankshaft position sensor lead grommet Quick Gasket ACC 11001 05 01 4 Install pickup coil rotor cover pickup coil lead holder clutch cable holder NOTE When installing the pickup coil rotor cover align the timing chain guide intake side pin 1 of the with the hole 2 in the pickup coil rotor cover Tighten the pickup coil rotor cover bolts in stages and in a crisscro...

Page 276: ...arks Removing the clutch cover Remove the parts in the order listed Bottom cowling and right side cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cable 1 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 For installation reverse the removal procedure ...

Page 277: ...rder Job Part Q ty Remarks Removing the pull lever shaft Remove the parts in the order listed 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal procedure ...

Page 278: ... the parts in the order listed 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 7 Inside diameter 124 mm 7 Clutch plate 6 8 Lock washer 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 1 Inside diameter 135 mm 12 Clutch damper spring 1 13 Clutch damper spring seat 1 14 Clutch boss 1 ...

Page 279: ...ft lb T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 15 Thrust washer 1 16 Clutch housing 1 17 Bearing 1 18 Starter clutch gear 1 19 Bearing 1 20 Starter clutch assembly 1 21 Circlip 1 22 Starter clutch idle gear 1 For installation reverse the removal procedure ...

Page 280: ...tch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering Universal clutch holder YM 91042 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Re...

Page 281: ...h plate warpage limit 0 1 mm 0 004 in EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE _ Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check bearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pi...

Page 282: ...T AND PULL ROD 1 Check pull lever shaft pinion gear teeth 1 pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 2 Check pull rod bearing Damage wear Replace EAS00348 CHECKING THE STARTER CLUTCH 1 Check starter clutch idle gear starter clutch drive gear starter clutch gear Burrs chips roughness wear Replace the defective part s ...

Page 283: ...drive gear counterclockwise É it should turn freely otherwise the starter clutch is faulty and must be replaced EAS00299 INSTALLING THE CLUTCH 1 Install clutch boss 1 lock washer clutch boss nut 2 2 Tighten clutch boss nut LOCTITE NOTE _ While holding the clutch boss with the univer sal clutch holder 3 tighten the clutch boss nut 3 Bend the lock washer tab along a flat side of the nut 4 Lubricate ...

Page 284: ... in stages and in a crisscross pattern 7 Install pull lever NOTE _ Install the pull lever with the mark facing towards the clutch cover T R 8 Nm 0 8 m kg 5 8 ft lb 8 Install clutch cover NOTE _ When installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinio...

Page 285: ...shift shaft and stop per lever Remove the parts in the order listed Drive sprocket cover Refer to ENGINE 1 Throttle stop screw holder 1 2 Shift shaft cover 1 3 Shift shaft cover gasket 1 4 Dowel pin 2 5 Shift shaft 1 6 Shift shaft spring 1 7 Spacer 1 8 Stopper lever spring 1 9 Stopper lever 1 10 Shift shaft spring stopper 1 For installation reverse the removal procedure ...

Page 286: ...all shift shaft spring stopper 1 stopper lever spring 2 stopper lever 3 NOTE Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly T R 22 Nm 2 2m kg 16 ft lb 2 Install shift shaft 1 spacer NOTE Lubricate the oil seal lips with lithium soap bas...

Page 287: ...rt Q ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly and water pump outlet pipe Refer to RADIATOR and OIL COOLER in chapter 6 Exhaust pipe assembly Refer to ENGINE 1 Oil level switch connector 1 Disconnect 2 Oil level switch 1 3...

Page 288: ...R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 7 Drain pipe 1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Oil water pump assembly drive sprocket cover 1 12 Dowel pin 1 13 Oil water pump assembly 1 14 Relief valve assembly 1 For installation reverse the removal procedure ...

Page 289: ... ft Ib Order Job Part Q ty Remarks Disassembling the oil pump Remove the parts in the order listed 1 Oil water pump assembly driven sprocket 1 2 Washer 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For assembly reverse the disassembly procedure ...

Page 290: ...e defec tive part s 2 Measure inner rotor to outer rotor tip clearance È outer rotor to oil pump housing clearance É oil pump housing to inner rotor and outer rotor clearance Ê Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 01 0 10 mm 0 0004 0 0039 in Limit 0 18 mm 0 0071 in Outer rotor to oil pump housing clearan...

Page 291: ... relief valve 2 spring 3 O ring 4 Damage wear Replace the defective part s EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with solvent ...

Page 292: ...housing screw NOTE _ When installing the inner rotor align the pin 1 in the oil pump shaft with the groove a in the inner rotor 2 3 Check oil pump operation Refer to CHECKING THE OIL PUMP Recommended lubricant Engine oil T R 10 Nm 1 0 m kg 7 2 ft lb EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump NOTE _ Install the oil water pump drive chain 1 onto the oil water pump driven sprocket 2 T R 15 N...

Page 293: ...T R 10 Nm 1 0 m kg 7 2 ft lb EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket oil pan 1 oil level switch 2 engine oil drain bolt 3 WARNING _ Always use new copper washers NOTE _ Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 43 Nm 4 3 m kg 31 ft lb ...

Page 294: ...fer to ENGINE Cylinder head Refer to CYLINDER HEAD Pickup coil and pickup coil rotor Refer to PICKUP COIL Stator coil assembly Refer to GENERATOR Clutch housing and starter clutch idle gear Refer to CLUTCH Oil water pump assembly Refer to OIL PAN AND OIL PUMP 1 Timing chain 1 2 Crankshaft sprocket 1 3 Pin 1 4 Oil water pump assembly drive chain guide 1 5 Oil water pump assembly drive chain 1 ...

Page 295: ... 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 6 Washer 1 7 Oil water pump assembly drive sprocket 1 8 Washer 1 9 Plate 1 10 Lower crankcase 1 11 Dowel pin 3 For installation reverse the removal procedure ...

Page 296: ...r crankcase CAUTION _ Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly M9 105 mm bolts 1 0 M8 50 mm bolt L M8 60 mm bolt K M6 45 mm bolts J P R M6 50 mm bolt H M6 55 mm bolts A E M6 60 mm bolt M M6 65 mm bolt Q M6 65 mm bolts F N...

Page 297: ...s Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace CHECKING THE SPROCKET AND CHAINS 1 Check crankshaft sprocket 1 oil water pump assembly drive sprocket 2 Cracks damage wear Replace the defec tive part s 2 Check timing chain 1 Damage stiffness Replace the timing chain and crankshaft sprocket as a set oil water...

Page 298: ...or crankshaft journal bear ings Do not apply sealant to within 2 3 mm of the crankshaft journal bearings 3 Install dowel pin Quick Gasket ACC 11001 05 01 4 Install crankshaft journal lower bearings 1 into the lower crankcase NOTE _ Align the projections a on the crankshaft journal lower bearings with the notches b in the lower crankcase Install each crankshaft journal lower bearing in its original...

Page 299: ...ne oil Tighten the bolts in increasing numerical order Install washers on bolts 1 0 M9 105 mm bolts 1 0 M8 50 mm bolt L M8 60 mm bolt K M6 45 mm bolts J P R M6 50 mm bolt H M6 55 mm bolts A E M6 60 mm bolt M M6 65 mm bolt Q M6 65 mm bolts F N M6 70 mm bolts G I O T R Crankcase bolt Bolt 1 0 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb 41 46 or 32 Nm 3 2 m kg 23 ft lb Bolt A E G J M O R ...

Page 300: ...oving the connecting rods and pistons Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal procedure ...

Page 301: ... so that it can be reinstalled in its original place 2 Remove piston pin clips 1 piston pin 2 piston 3 CAUTION _ Do not use a hammer to drive the piston pin out NOTE _ 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 area If both areas are deburred and the pis ton pin is still di...

Page 302: ...rankcase NOTE _ Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place EAS00261 CHECKING THE CYLINDER AND PISTONS 1 Check piston wall cylinder wall Vertical scratches Replace the cylinder and the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE _ Measure cy...

Page 303: ...5 minimum of D2 D4 or D6 c Measure piston skirt diameter P with the micrometer a 5 mm from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification replace the cylinder and the piston and piston rings as a set Piston size P 73 975 73 990 mm 2 9124 2 9130 in ...

Page 304: ...nder with the piston crown a 5 mm 0 20 in 3 Measure piston ring end gap Out of specification Replace the piston ring NOTE _ The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 ...

Page 305: ... diameter b Out of specification Replace the piston 4 Calculate piston pin to piston clearance Out of specification Replace the piston pin and piston as a set CHECKING THE BIG END BEARINGS 1 Measure crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings Piston pin bore inside diameter 17 002 17 013 mm 0 6694 0 6698 in Limit 17 043 mm 0 6710 in Piston pin to p...

Page 306: ...to the connecting rod and the big end lower bear ing into the connecting rod cap NOTE 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 the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricat...

Page 307: ...e 120 WARNING When the nut is tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified angle Tighten the nut until it is at the specified angles NOTE When using a hexagonal nut note that the angle from one corner to another is 60 k Remov...

Page 308: ...ing rod P1 and the crankshaft web P1 numbers are 4 and 1 respectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 2 5 1 2 2 black BIG END BEARING COLOR CODE 1 violet 0 white 1 blue 2 black INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons 1 Install top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lo...

Page 309: ... to the illustration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil New 4 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5 Lubricate crankshaft pins big end bearings connecting rod...

Page 310: ...with the other hand Make sure that the Y marks a on the con necting rods face towards the left side of the crankshaft Make sure that the characters b on both the connecting rod and connecting rod cap are aligned 7 Align bolt heads with the connecting rod caps 8 Tighten connecting rod nuts a Replace the connecting rod bolts and nuts with new ones CAUTION Tighten the connecting rod bolts using the p...

Page 311: ...the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified angle Tighten the nut until it is at the specified angles NOTE When using a hexagonal nut note that the angle from one corner to another is 60 ...

Page 312: ...aft assembly Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal procedure ...

Page 313: ...ournal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION _ Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crankshaft journals and be...

Page 314: ... the lower crankcase and assemble the crankcase halves NOTE _ Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clear ance measurement has been completed f Tighten the bolts to specification in the tight ening sequence cast on the crankcase NOTE _ Lubricate the crankcase bolt threads with engine oil T R C...

Page 315: ...eb and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings if the size is the same for all J1 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J1 and crank shaft ...

Page 316: ...kshaft journal upper bearings 1 into the upper crankcase NOTE _ Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 2 Install crankshaft ...

Page 317: ...ks Removing the transmission shift drum assembly and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Stopper lever Refer to SHIFT SHAFT 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 1 6 Shift fork guide bar 2 7 Spring 4 8 Shift fork L 1 9 Shift fork R 1 ...

Page 318: ...RANSMISSION T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 For installation reverse the removal procedure ...

Page 319: ...he main axle assembly Disassembly the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd 4th pinion gears 1 9 5th pinion gear 1 0 Collar 1 ...

Page 320: ...5 84 ENG TRANSMISSION Order Job Part Q ty Remarks A Main axle 1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For assembly reverse the disassembly procedure ...

Page 321: ...assembling the drive axle assembly Disassembly the parts in the order listed 1 Washer 1 2 1st wheel gear 1 3 Spacer 1 4 5th wheel gear 1 5 Circlip 3 6 Washer 3 7 3rd wheel gear 1 8 Toothed spacer 2 9 Toothed lock washer 1 0 Toothed lock washer retainer 1 ...

Page 322: ...5 86 ENG TRANSMISSION Order Job Part Q ty Remarks A 4th wheel gear 1 B 6th wheel gear 1 C 2nd wheel gear 1 D Spacer 1 E Drive axle 1 F Bearing 1 G Spacer 1 For assembly reverse the disassembly procedure ...

Page 323: ... axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent shift fork guide ba...

Page 324: ...NG THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Main axle runout limit 0 08 mm 0 0031 in Drive axle runout limit 0 08 mm 0 0031 in 3 Check transmission gears Blue discoloration pitting wear Replace the de...

Page 325: ...ift fork R shift fork L springs shift fork guide bars drive axle assembly NOTE _ Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Ma...

Page 326: ... Refer to SEATS and FUEL TANK in chapter 3 Air filter case and rubber cover Refer to AIR FILTER CASE in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Drive sprocket cover Refer to ENGINE in chapter 5 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant reservoir hose 1 2 Coolant reservoir 1 RADIATOR 1 2 3 4 5 6 ...

Page 327: ...IATOR Order Job Part Q ty Remarks 3 Radiator inlet hose 1 4 Radiator outlet hose 1 5 Water pump breather hose 1 6 Radiator 1 7 Radiator fan 1 8 Water pump inlet pipe 1 For installation reverse the removal procedure ...

Page 328: ...adiator cap opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 95...

Page 329: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 330: ...emove the parts in the order listed Radiator assembly Refer to RADIATOR Exhaust pipe assembly Refer to ENGINE in chapter 5 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler outlet hose 1 2 Bolt 1 3 Lock washer 1 4 Oil cooler 1 5 Oil cooler inlet hose 1 6 Water pump outlet pipe 1 7 Water jacket joint inlet hose 1 8 Water jacket joint 1 For installation reverse the removal ...

Page 331: ...O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Bend the lock washer tab along a flat side of the bolt 4 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount of the recom mended engine oil R...

Page 332: ...ider seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Air filter case and rubber cover Refer to AIR FILTER CASE in chapter 3 Throttle body assembly Refer to THROTTLE BODIES in chap ter 7 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator inlet hose 1 2 Thermostat assembly breather hose 1 3 Thermostat assembly inlet hose left 1 4 Thermostat assembly inlet pipe right 1 ...

Page 333: ...L THERMOSTAT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Thermostat assembly 1 6 Thermostat assembly inlet pipe left 1 For installation reverse the removal procedure ...

Page 334: ... ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Disassembling the thermostat housing Remove the parts in the order listed 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly procedure ...

Page 335: ...e a thermometer in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature 1 Thermometer 2 Water 3 Thermostat 4 Container È Fully closed É Fully open NOTE _ If the accuracy of the thermostat 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 Re...

Page 336: ...ling the thermo switch and temperature sender Replace any part that was dropped or sub jected to a strong impact EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified p...

Page 337: ...e water pump and oil pump are com bined into one unit oil water pump assembly It is not necessary to remove the impel ler shaft unless the coolant level is extremely low or coolant leaks from the oil pan Oil water pump assembly and oil pump rotor Refer to OIL PAN AND OIL PUMP in chapter 5 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 ...

Page 338: ...6 13 COOL WATER PUMP T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal procedure ...

Page 339: ...f the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE _ Do not scratch the impeller shaft EAS00473 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 water pump seals oil seal Cracks damage wear Replace 2 Check bearing Rough...

Page 340: ...lubricate the water pump seal sur face with oil or grease NOTE _ Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 or Quick Gasket 2 to the water pump housing 3 È Push down Mechanical seal installer 4 YM 33221 Middle driven shaft bearing driver 5 YM 4058 1 Quick Gasket ACC 11001 05 01 New New 3 Install rubber damper 1 rubber damper h...

Page 341: ...sure impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION _ Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Impeller shaft tilt limit 0 15 mm 0 0059 in ...

Page 342: ...ssure sensor 9 Throttle position sensor 0 Fuel injector A Catalytic converter B Crankshaft position sensor C Coolant temperature sensor D Spark plug E Cylinder identification sensor F Pressure regulator G Battery H ECU I Atmospheric pressure sensor J Fuel injection system relay K Engine trouble warn ing light L Lean angle cut off switch M Air cut off valve FUEL INJECTION SYSTEM 1 2 3 4 5 6 7 ...

Page 343: ... B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B L Y L B BLACK BLACK BLACK BLACK BLACK BLACK D G G W W B L W R W Y W B G W E E Y G L P W B L B L L P B L B L B L Br W Br W G Sb W Sb W A E Y B Y B B Br R W A A C C C Ch Ch A A A Y L Y L B G L L L Y F ...

Page 344: ...U memory until a deletion operation is performed Engine trouble warning light indication and FI system operating conditions This control is effected when any one of the conditions listed below is present and the starter switch is turned ON Function to check for blown engine trouble warning light bulb The engine trouble warning light illuminates for 1 4 seconds after the main switch has been turned...

Page 345: ...r toward the open side for 3 seconds and then stop it Able Able 18 EXUP servo motor lock A lock EXUP servo motor is detected Perform the preventive control against motor locking Preform the lock release operation twice every 100 seconds Able Able 19 Sidestand switch open circuit in wire to ECU Open circuit is detected in the input line from the sidestand switch to the ECU No start Unable Unable 20...

Page 346: ...ement method in the troubleshooting details Repair Completion Checking the meter display Check whether the self diagnostic fault code num ber is shown after turning the main switch OFF once and then turning it back ON Not displayed Erasing the malfunction history Malfunction history will be stored even if the main switch is turned OFF To erase the malfunction his tory it is required to operate to ...

Page 347: ...disappear except the clock and trip indications Letters dlAG appear on the clock LCD 3 Using the SELECT button select either the CO adjustment mode which appears as CO or the diagnosis mode which appears as dlAG 4 After dlAG appears as a result of pressing the SELECT button simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 5 Disconnect the wiring harn...

Page 348: ...sensor 01 16 A stuck throttle position sensor is detected Stuck throttle position sensor Malfunction in ECU 01 17 EXUP servo motor potention circuit open or short circuit detected Open or short circuit in wiring sub lead Detected EXUP servo motor potention circuit 53 18 EXUP servo motor is stuck Open or short circuit in wiring sub lead Stuck EXUP servo motor mechanism Stuck EXUP servo motor motor ...

Page 349: ...sor or an open or short circuit is detected in the neutral switch Open or short circuit in wiring harness Defective speed sensor Malfunction in vehicle speed sensor detected unit Defective neutral switch Malfunction in the engine side of the neutral switch Malfunction in ECU 07 21 43 The ECU is unable to monitor the bat tery voltage an open circuit in the monitor line to the ECU Open circuit in wi...

Page 350: ...played on the meter 06 Coolant temperature Displays the coolant temperature Check the temperature of the coolant Compare it to the value dis played on the meter 07 Vehicle speed pulse Displays the accumulation of the vehicle pulses that are gen erated when the tire is spun 0 999 resets to 0 after 999 OK if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off...

Page 351: ...f the engine stop switch is ON turn it OFF once and then turn it back ON Check the operating sound of the injector five times with engine stop switch ON 39 Injector 4 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON it actuates the injec tor five times every second and illuminates the engine trouble warning light If the engine stop switch is ON turn it...

Page 352: ...t has been detected as a self diagnostic fault code 44 If multiple malfunctions have been detected different codes are displayed at 2 second intervals and this process is repeated 01 04 Displays the cylinder number 00 Displays when there is no malfunction 61 Malfunction history code display Displays the codes of the history of the self diagnosis mal functions i e a code of a malfunction that occur...

Page 353: ...instated by starting the engine and operating it at idle Defective cylinder identification sensor Replace if defective 1 Connect the pocket tester DC 20 V to the cylinder identification sensor coupler termi nal as shown 2 Set the main switch to ON 3 Measure the cylinder identification sensor output voltage 4 Is the cylinder identification sensor OK Defective starter motor Replace if defective Refe...

Page 354: ...nkshaft position sensor coupler as shown 3 Measure the crankshaft position sensor resistance 4 Is the crankshaft position sensor OK Open or short circuit in wiring harness Repair or replace if there is an open or short circuit between the main wiring harnesses Between sensor coupler and ECU coupler Gray Gray Black Blue Black Blue Connected condition of connector Inspect the coupler for any pins th...

Page 355: ...ltage 4 Is the intake air pressure sensor OK Reinstated by turn ing the main switch ON Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Pink White Pink White Blue Blue Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking cond...

Page 356: ...rn ing the main switch ON Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Yellow Yellow Blue Blue Installed condition of throttle position sensor Check the installed area for looseness or pinching Check that it is installed in the specified posi tion Refer to THROTTLE BODIES ...

Page 357: ... the EXUP servomotor resistance 4 Is the EXUP servomotor OK Reinstated by turn ing the main switch ON Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between motor coupler and ECU coupler Blue Blue White Red White Red Black Blue Black Blue Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condit...

Page 358: ...ging the EXUP servomo tor perform this test within a few seconds of connecting the battery 5 Does the EXUP servomotor pulley turn Reinstated by turn ing the main switch ON It takes 120 sec onds at the maxi mum before the original state returns Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between motor coupler and ECU coupler Black Green Black Green B...

Page 359: ... clogged kinked or pinched Atmospheric pressure sensor hose is clogged Repair or replace the sensor hose Reinstated by turn ing the main switch ON Defective intake air pressure sensor or atmo spheric pressure sensor Replace if defective Refer to Fault code No 13 or No 23 Fault code No 21 Symptom Open or short circuit is detected from the coolant temperature sensor Used diagnostic code No 06 coolan...

Page 360: ...intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 4 Is the intake air temperature sensor OK Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Brown White Br...

Page 361: ...spheric air pressure sensor OK Reinstated by turn ing the main switch ON Open or short circuit in wiring harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Blue Blue Black Blue Black Blue Pink Pink Installed condition of atmospheric pressure sensor Check the installed area for looseness or pinching Connected condition of connector Inspect the coup...

Page 362: ...ean angle cut off switch approx 65 the voltage reading is 1 0 V to 4 0 V 5 Is the emergency stop switch OK Reinstated by turn ing the main switch ON however the engine cannot be restarted unless the main switch is first turned OFF The motorcycle has overturned Raise the motorcycle upright Installed condition of the lean angle cut off switch Check the installed area for looseness or pinching Connec...

Page 363: ... operating it at idle In case of multiple cylinder open or short circuit in lead make sure to turn ON and OFF the main switch after each time of crank ing Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between ignition coil coupler 2 and ECU coupler main harness Gray Red Gray Red Red Black Red Black Connected condition of connector Inspect the coupler for...

Page 364: ...r any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Ignition coil primary side coupler Gray Green Main wiring harness ECU coupler Fault code No 41 Symptom Open or short circuit detected in the lean angle cut off switch Used diagnostic code No 08 lean angle cut off switch Inspection operation item and probable ca...

Page 365: ... detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 Connected condition of speed sensor connec tor Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Speed sensor coupler Main wiring harness ECU coupler Defective neutral switch Replace if defective R...

Page 366: ...el injection system relay is on Malfunction or open circuit in fuel injection sys tem relay Replace if defective 1 Disconnect the starting circuit cut off relay from the wire harness 2 Connect the pocket tester Ω 1 and bat tery 12 V to the starting circuit cut off relay terminals as shown 3 Does the starting circuit cut off relay have continuity between blue white and black Connected condition of ...

Page 367: ...lty cylinder If there are mul tiple cylinders the number of the faulty cylinders appear alternately at 2 second intervals Replace ECU if defective Reinstated by turn ing the main switch ON Fault code No 50 Symptom Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Used diagnostic code No Inspection operation item and probable cause Op...

Page 368: ... is an open or short circuit Between sensor coupler and ECU coupler Yellow Red Yellow Red Black White Black White Reinstated by turn ing the main switch ON Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring...

Page 369: ...is an open or short circuit Between sensor coupler and ECU coupler Yellow Red Yellow Red Black White Black White Reinstated by turn ing the main switch ON Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring ...

Page 370: ...order listed Seats fuel tank rubber sheet Refer to SEATS and FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Sub wire harness 2 coupler 3 Disconnect 2 Throttle stop screw 1 3 Throttle body joint clamp screw 8 Loosen 4 Throttle bodies 1 ...

Page 371: ...7 30 FI THROTTLE BODIES Order Job Part Q ty Remarks 5 Throttle cable 2 Disconnect 6 Plunger control unit hose 2 Disconnect 7 Throttle body joint 4 For installation reverse the removal procedure ...

Page 372: ...upler 1 Disconnect 2 Intake air pressure sensor 1 Disconnect 3 Cylinder 1 injector coupler 1 Disconnect 4 Cylinder 2 injector coupler 1 Disconnect 5 Cylinder 3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 2 1 8 Negative pressure hose 1 Disconnect 9 Fuel injection pipe 1 10 Pressure regulator 1 ...

Page 373: ...7 32 FI THROTTLE BODIES Order Job Part Q ty Remarks 11 Intake air pressure sensor 1 12 Fuel distributor 1 13 Injector 4 14 Throttle position sensor 1 For installation reverse the removal procedure ...

Page 374: ... 1 Check injector Damage Replace CHECKING THE THROTTLE BODY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of passages with compressed air ...

Page 375: ... mity vac 2 onto the negative pressure hose from the pressure regulator d Connect the pressure gauge 3 and adapter 4 onto the fuel injection pipe e Install the fuel tank Refer to SEATS and FUEL TANK in chapter 3 f Start the engine g Measure the fuel pressure h Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below NOTE The vacuum pr...

Page 376: ...ect the throttle position sensor cou pler b Remove the throttle position sensor from the throttle body c Connect the pocket tester Ω 1k to the throttle position sensor d Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor e Connect the pocket tester Ω 1K to the throttle position sensor Positive tester probe blue terminal 1 Negative tes...

Page 377: ...y from those specified 2 Adjust throttle position sensor angle a Connect the throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the throt tle position sensor c Measure the throttle position sensor volt age d Adjust the throttle position sensor angle so the measured voltage is within the specified range e After adjusting the throttle position sensor angle t...

Page 378: ...d exhaust gases is approximately 600 to 700 C 1 100 to 1 300 F EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the 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 motorcycle is being driven However if the coolant tem perature is below the specifie...

Page 379: ...7 38 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut off valve 2 Reed valve 3 Air cleaner È To cylinder 1 É To cylinder 2 Ê To cylinder 3 Ë To cylinder 4 ...

Page 380: ...cks damage Replace pipes Cracks damage Replace 2 Check reed valve 1 reed valve stopper reed valve seat Cracks damage Replace the reed valve 3 Measure reed valve bending limit a Out of specification Replace the reed valve 1 Surface plate Reed valve bending limit 0 4 mm 0 016 in 4 Check air cut off valve Cracks damage Replace ...

Page 381: ...oupler from the wire harness b Connect the pocket tester Ω 1 to the AI system solenoid terminal as shown c Measure the AI system solenoid resistance d Out of specification Replace Tester positive probe orange 1 Tester negative probe green 2 Al system solenoid resistance 18 22 Ω at 20 C 68 F ...

Page 382: ...x 2 Front brake switch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuel injection system fuse 7 Main fuse 8 Neutral switch 9 Rear brake switch 0 Sidestand switch A Oil level switch B Radiator fan motor C Horn D Ignition coil ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 ...

Page 383: ...r 3 Intake air pressure sensor 4 Lean angle cut off switch 5 Atmospheric pressure sensor 6 ECU 7 Starting circuit cut off relay 8 Turn signal relay 9 Speed sensor 0 Crankshaft position sensor A Cylinder identification sensor B Radiator fan motor relay C Headlight relay 1 D Headlight relay 2 ...

Page 384: ...ket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration N...

Page 385: ...r to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 1 Main switch 2 Dimmer switch 3 Clutch switch 4 Horn switch 5 Turn signal switch 6 Sidestand switch 7 Engine stop switch 8 Start switch 9 Front brake light switch 0 Oil level gauge A Neutral switch B Rear brake light switch ...

Page 386: ... The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs C is used for turn signal and tail brake lights and can be removed from the socket b...

Page 387: ... other wise 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 clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range Pocket tester YM 031...

Page 388: ...dicate no continuity replace the bulb socket CHECKING THE LEDs The following procedures applies to all of the LEDs 1 Check LED for proper operation Improper operation Replace a Disconnect the meter assembly coupler meter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown WARNING _ A wire that is used as a jumper lead must have at lea...

Page 389: ... L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B L Y L B BLACK BLACK BLACK BLACK BLAC...

Page 390: ...ter YM 03112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery terminal...

Page 391: ...The ignition system is OK 5 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil leads from the wire harness Connect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe ignition coil terminal Negative tester probe ignition coil terminal Measure the primary coil resistance Primary coil resistance 1 19 1 61 Ω at 20 C...

Page 392: ...aft position sensor OK YES NO Replace the crankshaft position sensor 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK YES NO Replace the main switch 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK YES NO Replace the right handlebar switch 9 Neutral switch Check the n...

Page 393: ...r probe blue black 2 Continuity Positive tester probe blue black 2 Negative tester probe blue yellow 1 No continuity NOTE _ When you switch the positive and negative tester probes the readings in the above chart will be reversed Are the tester readings correct YES NO Replace the starting circuit cut off relay 12 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignit...

Page 394: ...G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B L Y L B BLACK BLACK BLACK B...

Page 395: ...ff relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHE...

Page 396: ...ition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery terminals Recharge or replace the bat tery 3 Starter motor Connect th...

Page 397: ...from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay coupler as shown Positive battery terminal red white 1 Negative battery terminal blue white 2 Positive tester probe red 3 Negative tester probe black 4 Does the starter relay have continuity between red and black YES NO Replace the starter relay 6 Main switch Check the main switch for continuity Refer to CHECKING...

Page 398: ... Refer to CHECKING THE SWITCHES Is the clutch switch OK YES NO Replace the clutch switch 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES NO Replace the right handlebar switch 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects YES NO The st...

Page 399: ...t Q ty Remarks Removing the starter motor Remove the parts in the order listed Rider seat Refer to SEATS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Left side cowling Refer to COWLINGS in chapter 3 1 Throttle stop screw 1 2 Starter motor lead 1 3 Starter motor assembly 1 For installation reverse the removal procedure ...

Page 400: ...Remarks Disassembling the starter motor Disassembly the parts in the order listed 1 Starter motor rear cover 1 2 Bearing 1 3 Starter motor yoke 1 4 O ring 2 5 Armature assembly 1 6 Brush 2 7 Brush holder 1 8 Starter motor front cover 1 9 Bearing 1 For assembly reverse the disassembly procedure ...

Page 401: ...ator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Commutator wear limit 23 5 mm 0 93 in Mica undercut 1 5 mm 0 059 in 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification repla...

Page 402: ... wear Replace the gear EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE _ Align the tab a on the brush seat with the slot b in the starter motor rear cover Brush spring force 5 28 7 92 N 528 792 g 19 01 28 51 oz 2 Install armature 1 3 Install starter motor yoke 2 O rings 1 starter motor rear cover 3 bolts NOTE Align the match marks a on the starter motor yoke with the match marks ...

Page 403: ...RCUIT DIAGRAM BLACK R Br L R Br L L Y L B L B L Y R B GRAY W W W ON OFF R W R W L W R W L W R R R R B B B B B R W R B R B R W W W W W R W B R Br L Br L L B R W L Y RED RED R R G 1 2 3 4 5 8 6 7 9 w 2 AC magneto 3 Rectifier regulator 5 Battery 6 Fuse main ...

Page 404: ... 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery terminals Recharge or replace the bat tery 3 Charging voltage Set the engine tachometer to the ignition coil of cylinder 1 Connect the pocket tester DC 20 V to the battery as shown Positive tester p...

Page 405: ...ite 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 19 0 23 Ω at 20 C 68 F Is the stator coil OK YES NO Replace the stator coil assembly 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly connected and without defects YES NO Replace the rectifier regulator Properly connec...

Page 406: ... Gy L B Y R G B R L R B Y R Y B Br R B3 B3 Gy R Gy G O O G B Y R B R R G B B B3 B3 B2 W P L Y G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy ...

Page 407: ...ain switch 5 Battery 6 Fuse main C ECU X Hi beam indicator light Meter light c Dimmer switch l Auxiliary light m Headlight n License light o Taillight u Headlight relay on off v Headlight relay dimmer x Fuse signal y Fuse headlight ...

Page 408: ...2 1 Main signal and headlight fuses Check the main signal and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signal and headlight fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the batt...

Page 409: ...lay dimmer from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay dimmer coupler as shown Low beam Positive tester probe black blue 1 Negative tester probe black green 2 Hi beam Positive battery lead yellow 1 Negative battery lead black 2 Positive tester probe black blue 3 Negative tester probe black yellow 4 Does the headlight relay dimmer have continuity Replace ...

Page 410: ...When the dimmer switch is set to É When the dimmer switch is set to Headlight coupler wire harness side Headlight Positive tester probe black yellow 1 or black green 2 Negative tester probe black 3 High beam indicator light Positive tester probe black yellow 4 Negative tester probe black white 5 Meter light coupler wire harness side Set the main switch to ON Start the engine and headlight to ON Se...

Page 411: ...ithin specification YES NO This circuit is OK The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired 1 Tail brake light bulb and socket Check the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the tail brake light bulb and socket OK YES NO Replace the tail brake light bulb socket or both 2 Voltage Connect ...

Page 412: ...hin specification YES NO This circuit is OK The wiring circuit from the main switch to the auxiliary light connectors is faulty and must be repaired 1 License plate light bulb and socket Check the license plate light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK YES NO Replace the license plate light bulb socket or both 2...

Page 413: ...B Gy L B Y R G B R L R B Y R Y B Br R B3 B3 Gy R Gy G O O G B Y R B R R G B B B3 B3 B2 W P L Y G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy...

Page 414: ...ght U Neutral indicator light W Coolant temperature indicator light Y Turn signal indicator light L Z Turn signal indicator light R Oil level gauge _ Flasher relay b Multi function meter d Horn switch f Turn signal switch g Front flasher light L h Front flasher light R i Rear flasher light L j Rear flasher light R k Horn p Tail brake light q Rear brake switch r Front brake switch w Fuse ignition x...

Page 415: ...r YM 03112 1 Main ignition signaling and back up fuses Check the main ignition signaling and back up fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition signaling and back up fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F ...

Page 416: ...switch Does the horn sound NO YES Replace the horn The horn is OK 1 Tail brake light bulb and socket Check the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the tail brake light bulb and socket OK YES NO Replace the tail brake light bulb socket or both 2 Brake light switches Check the brake light switches for continuity Refer to CHECKING THE SWITC...

Page 417: ...arness side as shown Positive tester probe brown 1 Negative tester probe ground Set the main switch to ON Measure the voltage DC 12 V on brown 1 at the turn signal relay coupler wire harness side Is the voltage within specification YES NO The wiring circuit from the main switch to the turn signal relay cou pler is faulty and must be repaired 4 Voltage Connect the pocket tester DC 20 V to the turn ...

Page 418: ...or light bulb and socket Check the neutral indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the neutral indicator light bulb and socket OK YES NO Replace the neutral indicator light bulb socket or both 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES NO Replace the neutral switch 3 Vo...

Page 419: ...evel gauge resis tanse Oil level gauge resistance 108 132 Ω at 20 C 526 624 Ω at 20 C Is the engine oil level gauge OK YES NO Replace the engine oil level gauge 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe black red 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage DC 12 V of black red 1...

Page 420: ...e pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe green white 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage DC 12 V of green white 1 and black white 2 at the meter assembly coupler Is the voltage within specification YES NO This circuit is OK The wiring circuit from the main switch to the meter assem bly cou...

Page 421: ...e voltage within specification NO YES Replace the multi function meter 3 Speed sensor Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Positive tester probe white yellow 1 Negative tester probe blue 2 Set the main switch to ON Elevate the rear wheel and slowly rotate it Measure the voltage DC 5 V of yellow and black yellow With each full rotation of the rear...

Page 422: ... R R G B B B3 B3 B2 W P L Y G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B...

Page 423: ...e coolant temperature meter meter assembly fails to indicate when the engine is warm Pocket tester YM 03112 1 Main ignition and fan motor fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Min...

Page 424: ...y and must be replaced 5 Radiator fan motor relay Disconnect the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown Check the radiator fan motor of continuity Positive battery terminal red white 1 Negative battery terminal green yellow 2 Tester positive probe brown green 3 Tester negative probe blue 4 Does the ...

Page 425: ...sor for continuity at the temperatures indicated in the table Coolant temperature sensor resistance 0 C 32 F 5 21 6 37 kΩ 80 C 176 F 0 29 0 35 kΩ WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature sensor 20 Nm 2 0 m kg 14 ft lb Three bond seal...

Page 426: ...B3 B3 B2 W P L Y G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B L Y L B BL...

Page 427: ... EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 ECU 7 Fuel injection system fuse 8 Fuel injection system relay 9 Fuel pump ...

Page 428: ...tion system fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery terminals Recharge or replace the bat tery...

Page 429: ...ve continuity between red and red blue YES NO Replace the starting circuit cut off relay 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump coupler as shown Positive tester probe red blue 1 Negative tester probe black 2 Measure the fuel pump resistance Fuel pump resistance 0 2 3 0 Ω at 20 C 68 F Is the fuel pump OK YES NO Re...

Page 430: ...l gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check Fuel pump operation a Insert the plug 1 to fuel return hose end b Fill the fuel tank c Put the end of the fuel hose into an open container d Connect the battery DC 12 V to the fuel pump coupler ...

Page 431: ...sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYS...

Page 432: ...onnections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle...

Page 433: ...n gears Improperly assembled transmission JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction pla...

Page 434: ...y connected hose Damaged pipe Improperly connected pipe FUEL SYSTEM Throttle body ies Incorrect main jet setting Incorrect fuel level Damaged or loose throttle body joint Air filter Clogged air filter element CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty ignitor unit EAS00856 OVERCOOLING COOLING SYSTEM...

Page 435: ...t or improperly installed left handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tu...

Page 436: ... Faulty battery Incorrectly adjusted rear brake light switch TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect...

Page 437: ...vel warning light T Oil level warning light U Neutral indicator light V Tachometer W Coolant temperature indicator light X High beam indicator light Y Turn signal indicator light L Z Turn signal indicator light R Meter light Meter assembly Oil level gauge _ Turn signal relay a Left handlebar switch b Multi function meter c Dimmer switch d Horn switch e Clutch switch f Turn signal switch g Front tu...

Page 438: ...ORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G BLACK BLACK WIRE SUB LEAD 3 MAIN HARNESS F GRAY BLUE BLUE GRAY WIRE SUB LEAD 2 MAIN HARNESS E GRAY GRAY WIRE SUB LEAD 1 MAIN HARNESS D D CORD TAIL LIGHT MAIN HARNESS C CORD HEAD LIGHT MAIN HARNESS B R GRAY R N L ON OFF OFF ON HI LO OFF RUN FREE PUSH RED RED BROWN BROWN BLACK BLACK BLACK BLUE BLUE GRAY GRAY GRAY F GRAY F GRAY F GRAY F F D...

Page 439: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

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Yamaha YZF-R1(P) 2002, Service Manual

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