Yamaha YZF-R15 Service Manual Download Page 12 | Manualshive

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IMPORTANT INFORMATION

IMPORTANT INFORMATION

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND
DISASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS” on page 1-8.

3. When disassembling, always keep mated

parts together. This includes gears, cylinders,
pistons and other parts that have been “mated”
through normal wear. Mated parts must always
be reused or replaced as an assembly.

4. During disassembly, clean all of the parts and

place them in trays in the order of disassembly.
This will speed up assembly and allow for the
correct installation of all parts.

5. Keep all parts away from any source of fire.

REPLACEMENT PARTS

Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended
by Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil
seallips with grease.

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates “1”
and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals “1”, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.

Do not spin the bearing with compressed air
because this will damage the bearing
surfaces.

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the sharp-
edged corner “2” is positioned opposite the thrust
“3” that the circlip receives.

CAUTION :

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Summary of Contents for YZF-R15

Page 1: ...2008 SERVICE MANUAL YZF R15 20P F8197 E0 ...

Page 2: ...YZF R15 SERVICE MANUAL All rights reserved Any reproduction or unauthorized use without the written permission of YAMAHA MOTOR INDIA SALES PVT LTD is expressly prohibited ...

Page 3: ... Modifications and significant changes in specifications or procedures will be forwarded to all authorized YMIS dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice Particularly important information is distinguished in this manual by the following The SafetyAlert Symbol meansATTENTION BECOMEALERT YOUR SAFETY IS ...

Page 4: ...2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies t...

Page 5: ... 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a new one G M E B LS M 9 10 11 12 13 14 15 16 17 18 LT New BF S T R 1 2 3 4 5 6 7...

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

Page 7: ...TIFICATION NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 1 2 OUTLINE OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 1 4 PREPARATION FOR REMOVALAND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALSAND O RINGS 1 5 LOCK WASHERS PLATESAND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 1 7 1 8 GENERAL INFORMATION ...

Page 8: ...ATION NUMBER FRAME NO ENGINE SERIALNUMBER NOTE The vehicle identification number 1 is stamped into the frame The engine serial number 1 is stamped into the crankcase Designs and specifications are subject to change without notice 1 1 1 1 xx xx xx x ...

Page 9: ...the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner 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 t...

Page 10: ...the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor lean angle 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 sensor As a result the volum...

Page 11: ...rder ODO TRIP TRIP ODO When approximately 9 L of fuel remains in the fuel tank the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point and the last segment of the fuel meter will start flashing In that case pushing the RESET SELECT button switches the display between the various tripmeter and odometer modes i...

Page 12: ...y and allow for the correct installation of all parts 5 Keep all parts away from any source of fire REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OILSEALSAND O RINGS 1 When overhauling the engine replace all gaskets seals an...

Page 13: ...d grease Oil bearings liberally when installing if appropriate Do not spin the bearing with compressed air because this will damage the bearing surfaces CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that...

Page 14: ... times 1 2 Lead Coupler Connector 3 Check All connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up NOTE 4 Connect Lead Coupler Connector Make sure all connections are tight 5 Check Continuity with the multimeter NOTE 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 re...

Page 15: ...l is used to loosen and tighten tappet adjusting nut This tool is used to adjust the valve clearance by tappet adjusting screw YSST 706A Feeler gauge YSST 715 This tool is used to adjust the valve clearance in an engine Valve spring compressor YSST 603 This tool is used to remove and install Valve Spring Assemblies Magneto holder YSST 701 Magneto puller YSST 702 This tool is used to hold the magne...

Page 16: ...k Case Crank Shaft Installing Tool with Spacer a YSST 266 b YSST 267 These tools are used for installation of Crank Shaft a b Timing light Compression gauge This instrument is used to reset the ignition timing This instrument is used to measure the engine compression FI diagnostic tool This instrument is used to diagnose the electrical faults in fuel injection system Scraper YSST 612 This tool is ...

Page 17: ... This adapter is used to connect the radiator cap tester with radiator cap for radiator cap testing This instrument is used to offer the vacuum to air induction system for checking Steering nut wrench YSST 721 This tool is used to loosen and tighten the steering nut This tool is used to hold the TFF plunger for loosening and tightening of Hex Socket Head Bolt T handle YSST 713 This tool assists to...

Page 18: ...l the seal and bearing in water assy pump This instrument is used to check the effficiency of ignition at spark plug This instrument is used to check the electrical circuits or components Y amaha bond No 1215 This adhesive is used on mating surfaces while assem bling Crankcase 1 and 2 LOCTITE Three Bond 1322 This adhesive is used for tightening of Torx Screw ...

Page 19: ...BRICANT TYPES LUBRICATION SYSTEM CHARTAND DIAGRAMS COOLING SYSTEM DIAGRAMS CABLE ROUTING 2 1 2 2 2 9 2 12 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 2 22 ENGINE 2 22 CHASSIS 2 24 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 2 31 2 33 SPECIFICATIONS ...

Page 20: ...TIONS Model Dimensions Weight Model 20 P1 Overall length 1995 mm Overall width 670 mm Overall height 1070 mm Seat height 790 mm Wheelbase 1290 mm Ground clearance 160 mm Minimum turning radius 2500 mm With oil and fuel 131 kg Maximum load 199 kg ...

Page 21: ...Without oil filter element replacement L With oil filter element replacement L Oil filter type Paper Oil pump type Gear pump Inner rotor to outer rotor tip clearance Less than mm Limit mm Outer rotor to oil pump housing clearance mm Limit mm Oil pump housing to inner and outer rotor clearance mm Limit mm Rotor thickness mm Relief valve operating pressure kPa psi kgf cm Radiator capacity including ...

Page 22: ...pump Reduction ratio 0 500 Manufacturer model NGK CR8E Manufacturer model DENSO U24ESR N Spark plug gap 0 7 0 8 mm Volume 9 90 10 50 cm Warpage limit 0 03 mm Drive system Chain drive left Camshaft lobe dimensions IntakeA 25 177 0 05 mm Limit 25 027 mm Intake B 30 275 0 05 mm Limit 30 125 mm ExhaustA 25 115 0 05 mm Limit 24 965 mm Exhaust B 30 282 0 05 mm Limit 30 132 mm Camshaft runout limit 0 03 ...

Page 23: ...nsions Valve head diameterA intake 19 40 19 60 mm Valve head diameterA exhaust 16 90 17 10 mm Valve face width B intake 1 538 2 138 mm Valve face width B exhaust 1 538 2 138 mm Valve seat width C intake 0 90 1 10 mm Valve seat width C exhaust 0 90 1 10 mm Valve margin thickness D intake 0 50 0 90 mm Valve margin thickness D exhaust 0 50 0 90 mm Valve stem diameter intake 4 475 4 490 mm Limit 4 450...

Page 24: ...N mm Spring rate K2 intake 36 58 N mm Spring rate K1 exhaust 23 54 N mm Spring rate K2 exhaust 36 58 N mm Installed compression spring force intake 140 162 N Installed compression spring force exhaust 140 162 N Spring tilt intake 2 5 1 8 mm Spring tilt exhaust 2 5 1 8 mm Winding direction intake Clockwise Winding direction exhaust Clockwise Bore 56 985 57 010 mm Taper limit 0 05 mm Out of round li...

Page 25: ...ed mm Limit mm Ring side clearance mm Limit mm nd ring Ring type Taper Dimensions B xT 0 80 x 2 00 mm End gap installed mm Limit mm Ring side clearance mm Limit mm Oil ring Dimensions B xT 1 50 x 1 52 mm End gap installed mm Ring side clearance mm 5 0 0 25 14 002 14 013 14 043 13 995 14 000 13 975 0 002 0 018 0 068 0 10 0 25 0 40 0 030 0 065 0 100 2 0 10 0 25 0 40 0 020 0 055 0 100 0 20 0 70 0 040...

Page 26: ...lay 10 0 15 0 mm Friction plate thickness 2 90 3 10 mm Wear limit 2 80 mm Plate quantity 1 pc Friction plate 2 thickness 2 90 3 10 mm Wear limit 2 80 mm Plate quantity 4 pc Clutch plate thickness 1 45 1 75 mm Plate quantity 4 pcs Warpage limit 0 20 mm Clutch spring free length 39 00 mm Minimum length 36 80 mm Spring quantity 4 pcs Push rod bending limit 0 500 mm Transmission type Constant mesh 6 s...

Page 27: ...tput voltage V at kPa Intake air temperature sensor resistance k Coolant temperature sensor resistance at Engine idling speed r min Water temperature C 185 00 203 00 Oil temperature Throttle cable free play mm 2 30 16 1 875 3 30 2 1 4 24 21 1 143 5 22 23 0 957 5 76 5 89 1100 87 10 1 28 1 50 248 372 Ω 20 0 789 4 000 20 00 101 32 5 7 6 3 Ω 310 326 Ω 80 1300 1500 85 0 95 0 50 0 70 0 158 00 3 0 5 0 Sh...

Page 28: ...mm Radial wheel runout limit mm Lateral wheel runout limit mm Wheel type Cast wheel Rim size M C x MT2 15 Rim material Aluminum Wheel travel 05 mm Radial wheel runout limit mm Lateral wheel runout limit mm Type Tubeless Size 80 90 17M C 44P Manufacturer model MRF ZAPPER Type Tubeless Size 100 8 M C 52P Manufacturer model MRF ZAPPER Front 200 Rear 25 kPa Type Single disc brake Operation Right hand ...

Page 29: ...ree length 384 8 mm Limit 381 8 mm Collar length 88 0 mm Installed length 381 8 mm Spring rate K1 5 N mm Spring rate K2 6 75 N mm Spring stroke K1 0 75 0 mm Spring stroke K2 75 0 130 mm Inner tube outer diameter 33 0 mm Optional spring available No Recommended oil Fork oil 10W or equivalent Quantity 240 cm Level 126 0 mm Type Swingarm Link suspension Spring shock absorber type Coil spring oil damp...

Page 30: ...length 156 5 mm Spring rate K1 90 00 N mm Spring stroke K1 0 0 50 0 mm Optional spring available No Swingarm end free play limit axial 2 4 mm Type manufacturer 428VI3 DAIDO Link quantity 120 Drive chain slack 20 40 mm 15 link length limit 190 5 mm Swingarm Drive chain ...

Page 31: ...Kohms Model manufacturer F C PTMORIC Standard output V W rpm Stator coil resistance at Regulator type Semi conductor short circuit Regulated voltage DC V Rectifier capacity A Withstand voltage V Model VRLA Voltage capacity V Ah Ten hour rate amperage 3 50 A Bulb type Halogen bulb Headlight V x2 Tail brake light V W W x 1 Front turn signal light V W x 2 Rear turn signal light V W x 2 Meter lighting...

Page 32: ...sh spring force 3 92 5 88 N Commutator diameter 17 6 mm Limit 16 6 mm Mica undercut depth 1 35 mm Model manufacturer 5TP OMRON LOCAL Amperage 100A Coil resistance 3 42 4 18 Horn type Plane Quantity 1 pc Model manufacturer Local Made Maximum amperage 1 5A Coil resistance 4 30 4 80 at 20 C Performance 108 115 dB 2 m Relay type FullTransistor Model manufacturer Local Made Built in self canceling devi...

Page 33: ...2 14 ELECTRICAL SPECIFICATIONS Coil resistance 54 0 66 0 Fuse 20 0A Ω Fuse ...

Page 34: ...d warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8...

Page 35: ...0 m kg 7 2 ft lb Y amaha bond No 1215 Three bond 1215 Water pump assembly bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Water pump housing cover bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Impeller shaft retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Oil pump assembly screw M5 2 4 Nm 0 4 m kg 2 9 ft lb Engine oil drain plug M35 1 32 Nm 3 2 m kg 23 ft lb Oil filter elem...

Page 36: ...b Clutch cable locknut M8 1 9 Nm 0 9 m kg 6 5 ft lb Clutch lever nut M6 1 7 Nm 0 7 m kg 5 1 ft lb Clutch lever holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Drive sprocket retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Bearing retainer screw M6 2 7 Nm 0 7 m kg 5 1 ft lb Shift drum segment bolt M6 1 12 Nm 1 2 m kg 8 7 ft lb Stopper lever bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Stator coil bolt M6 3 10 Nm 1 0 m ...

Page 37: ...2 18 TIGHTENING TORQUES Cylinder head tightening sequence Magneto cover tightening sequence Clutch cover tightening sequence 4 2 6 5 3 1 2 10 3 11 4 5 1 6 7 8 9 11 2 12 10 9 9 6 8 1 7 3 13 6 5 4 ...

Page 38: ...2 19 TIGHTENING TORQUES Crankcase tightening sequence A 1 6 1 6 2 12 2 12 5 4 3 13 11 10 9 8 7 A Left crankcase B Right crankcase 14 15 B ...

Page 39: ...ft lb Drive chain cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Brake hose union bolt M10 2 26 Nm 2 6 m kg 19 ft lb Front brake caliper bolt M10 2 35 Nm 3 5 m kg 25 ft lb Front wheel axle nut M12 1 60 Nm 6 0 m kg 43 ft lb Front brake disc bolt M8 5 23 Nm 2 3 m kg 17 ft lb Bleed screw front brake caliper M7 1 6 Nm 0 6 m kg 4 3 ft lb Brake hose holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M...

Page 40: ...lb Rear side cover and rear panel bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Seat Handle M8 4 26 Nm 2 6 m kg 19 ft lb Coolant reservoir bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Radiator bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Radiator fan bolt M6 2 8 Nm 0 8 m kg 5 8 ft lb Grip end screw M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake master cylinder hold er bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake lever bolt M6 1 6 Nm 0...

Page 41: ...d exhaust Rocker arm shaft Rocker arm inner surfaces Decompression lever pin Oil seal clutch cover Oil pump driven gear Oil pump rotors inner and outer Starter clutch idle gear thrust surface Starter clutch idle gear shaft Starter clutch gear inner surface and thrust surface Starter clutch rollers Clutch push lever Primary driven gear inner surface Clutch push rod short and long and ball Clutch bo...

Page 42: ...haft position sensor stator assembly lead grommet Y amaha bond No 1215 Three Bond No 1215 Crankcase mating surface Y amaha bond No 1215 Three Bond No 1215 Timing chain tensioner bolts Y amaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 43: ...per bearing cover lip Steering head dust seal Bolt and nut threads relay arm and flame Bolt and nut threads connecting rod and relay arm Bolt and nut threads rear shock absorber and relay arm Bolt and nut threads connecting rod and swingarm Bearing inner surface relay arm and swingarm Oil seal lips relay arm and swingarm Collars relay arm and swingarm Pivot shaft and nut threads Pivot shaft outer ...

Page 44: ...2 25 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART 1 6 5 2 4 3 ...

Page 45: ...2 26 LUBRICATION POINTS AND LUBRICANT TYPES 2 Oil filter element 3 Crankshaft 4 Camshaft 5 Main axle 6 Drive axle 1 Oil pump ...

Page 46: ...2 27 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS A 1 2 3 4 5 6 7 ...

Page 47: ...2 28 LUBRICATION POINTS AND LUBRICANT TYPES 1 Clutch push lever 2 Main axle 3 Drive axle 4 Crankshaft 5 Oil filter 6 Oil pump assembly 7 Oil strainer A T o cylinder head ...

Page 48: ...2 29 LUBRICATION POINTS AND LUBRICANT TYPES 1 2 3 4 ...

Page 49: ...2 30 LUBRICATION POINTS AND LUBRICANT TYPES 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...

Page 50: ...2 31 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 2 3 4 1 5 7 6 4 ...

Page 51: ...2 32 COOLING SYSTEM DIAGRAMS 1 Coolant reservoir 2 Radiator inlet hose 3 Coolant reservoir hose 4 Radiator 5 Water pump 6 Radiator outlet hose 7 Water pump breather hose ...

Page 52: ...2 33 CABLE ROUTING CABLE ROUTING 1 5 2 3 6 4 8 7 ...

Page 53: ...TING 1 Head Light lead wire clamp 2 Front flasher lead wire left 3 Head light lead wire 4 Meter harness 5 Auxiliary harness 6 Front flasher lead wire right 7 Right Handle bar switch lead wire 8 Brake switch lead wire ...

Page 54: ...2 35 CABLE ROUTING A A B B C C A A C C B B A B C 1 2 3 4 5 4 5 6 6 7 8 9 10 11 10 11 12 12 ...

Page 55: ...cable 7 Ignition coil 8 Spark plug lead 9 Air induction system vacuum hose 10 Right handlebar switch lead 11 Front brake light switch lead 12 Front brake hose A Pass the wire harness through the guide B Pass the front brake hose through the guide C Fasten the grommet of front brake hose on position between lower bracket and headlight bracket ...

Page 56: ...2 37 CABLE ROUTING 1 2 5 4 3 ...

Page 57: ...2 38 CABLE ROUTING 1 ECU wiring harness clamp 2 Wire harness 3 Starter motor lead 4 Rear brake light switch lead 5 Rear brake hose ...

Page 58: ...2 39 CABLE ROUTING F F G G A A B B C C D D E E 3 3 4 6 8 9 10 10 11 14 14 15 16 17 18 19 D B A A B C D E F 1 2 3 4 5 6 7 8 9 10 11 12 13 F F G G D B C C A ...

Page 59: ...making sure to align the white tape on the leads and cable with the tie B Fasten the sidestand switch lead coolant reservoir hose and fuel tank breather hose with the plastic clamp C Fasten the sidestand switch lead coolant reservoir hose and fuel tank breather hose to the left side cowling bracket with the plastic clamp D Fasten the wire harness to clutch switch and left handlebar switch lead to ...

Page 60: ...2 41 CABLE ROUTING A A B C D E 1 2 3 4 5 6 7 8 9 10 A ...

Page 61: ...lastic locking tie Do not cut off the excess end of the plastic locking tie B Fasten the crankshaft position sensor stator coil lead neutral switch lead and negative battery lead to the frame with the plastic locking tie Do not cut off the excess end of the plastic locking tie C Route the negative battery lead along the front of the pin D Pass the coolant reservoir breather hose and fuel drain pip...

Page 62: ...ank To avoid the bend follow the below mentioned sequence 1 Pass the drain 1 pipe across the fuel hose 2 as shown in illustration 1 3 Pass the fuel drain pipe and recovery tank breather hose from the slit of the mud guard 1 1 2 3 Pass the drain pipe 1 along with the recovery tank breather hose 2 from the slit at the frame comp 3 and adjust white paint 4 of fuel drain pipe 1 between these slits 4 R...

Page 63: ...2 44 CABLE ROUTING B A B C 1 2 3 4 5 6 7 8 9 10 11 12 13 C C E E A A D D B A A B B C C D D E E D 1 4 4 4 7 10 11 14 15 16 17 18 ...

Page 64: ... to horn 12 Clutch cable 13 Throttle cable 14 Wire harness to left handlebar switch 15 Front brake light switch lead 16 Right handlebar switch lead 17 Main switch lead 18 Cylinder head breather hose A Fasten the wire harness with the plastic locking tie B Fasten the fuel injector lead and FID fast idle solenoid lead with a plastic locking tie C Pass the clutch cable through the guide D Secure the ...

Page 65: ...2 46 CABLE ROUTING 1 2 3 4 5 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 B B B A J G H I F 9 10 C A C A B 18 19 B C 2 20 21 E D ...

Page 66: ...ush the starter motor lead and starter relay lead down into the space between the battery and the fender C Install the fuse box and then route the fuse box lead on top of the starter motor lead and starter relay lead D Connect the negative battery lead to the wire harness and then position the connector in the location shown in the illustration E Install the battery and then fasten all of the lead...

Page 67: ...3 13 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 13 CHECKING THE EXHAUST SYSTEM 3 13 CHECKING THE COOLING SYSTEM 3 14 CHANGING THE COOLANT 3 14 3 17 ADJUSTING THE REAR DISK BRAKE 3 17 CHECKING THE BRAKE FLUID LEVEL 3 17 CHECKING THE FRONT BRAKE PADS 3 18 CHECKING THE REAR BRAKE PADS 3 18 CHECKING THE FRONT BRAKE HOSE 3 18 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 19 ADJUSTING THE DRIVE CHAIN SLACK 3 20...

Page 68: ...TROUBLESHOOTING ELECTRICAL SYSTEM 3 26 CHECKING AND CHARGING THE BATTERY 3 26 CHECKING THE FUSE 3 26 REPLACING THE HEADLIGHT BULB 3 26 ADJUSTING THE HEADLIGHT BEAM 3 27 ...

Page 69: ...dition Clean and reset the gap Replace Check valve clearance Adjust Clean Replace Check Battery output voltage Check operation Adjust Lubricate Lever Every 12000 km Every 12000 km Check operation fluid level and vehicle for fluid leakage Replace brake pads Check operation fluid level and vehicle for fluid leakage Replace brake pads Check for cracks or damage Replace Check runout and for damage Che...

Page 70: ... Adjust engine idling speed Change coolant Check operation Every 12000 km Every 10000 km on odometer Every 2 Years 25 26 27 28 Lubricate Check the air cut off valve reed valve and hose for damage Check operation Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Replace any damaged parts if necessary Adjust headlight beam if...

Page 71: ... valve l Reed valve plate Refer to AIR INDUCTION SYSTEM on page 7 9 l Cylinder head cover l Cylinder head cover gasket Refer to CYLINDER HEAD on page 5 6 4 Remove l Timing mark accessing screw 1 l Crankshaft end accessing screw 2 5 Measure l Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise ssssssssssssssssssssssss b Align the TDC mark a on the magnero rotor with t...

Page 72: ... l Air induction system vacuum hose Refer to AIR INDUCTION SYSTEM on page 7 9 l Spark plug cap 10 Install l Fuel tank Refer to FUEL TANK on page 7 1 l Seat l Front panels Refer to GENERAL CHASSIS on page 4 1 ADJUSTING THE ENGINE IDLING SPEED NOTE Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and ...

Page 73: ...itch to OFF 3 Disconnect l Self diagnosis signal connector 1 4 Connect l FI diagnostic tool 2 5 While press the MODE button 1 turn the main switch to ON NOTE l DIAG appears on the LCD 2 of the FI diag nostic tool l POWER LED Green 3 comes on 6 Press the UP button to select the CO adjust ment mode CO or the diagnostic mode DI AG 7 After selecting CO press the MODE but ton 8 Check that C1 appears on...

Page 74: ... specification Adjust 2 Adjust l Throttle cable free play Throttle body side a Loosen the locknut 1 on the accelerator ca ble b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side...

Page 75: ...eck l Electrode 1 Damage wear Replace the spark plug l Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean l Spark plug with a spark plug cleaner or wire brush 7 Measure l Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install l Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect l S...

Page 76: ...sing screw along with the O ring MEASURING THE COMPRESSION PRESSURE NOTE Insufficient compression pressure will result in a loss of performance 1 Measure l Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 2 Start the engine warm it up for several min utes and then turn it off 3 Remove l Right front panel Refer to GENERAL CHASSIS on page 4 1 4 Disconne...

Page 77: ...n page 4 1 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE l Place the vehicle on the centerstand l Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check l 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 engi...

Page 78: ...he following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Install new O ring 3 c Install the new oil filter element and the oil fil ter element cover 6 Check l Engine oil strainer Dirt Clean 7 Install l Engine oil strainer l Spring l O ring l Engine oil drain plug 8 Fill l Crankcase with the specified amount of the recom mended engine oil 9 Install l Engine oil fill...

Page 79: ...h cable free play Handlebar side a Pull back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting bolt 3 in direction a or b until the specified clutch cable free play is obtained d Tighten the locknut e Place the rubber cover in its original position NOTE If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine sid...

Page 80: ... CAUTION Never operate the engine without the air filter 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 throttle body turning leading to poor engine performance and possible overheating NOTE Make sure the air filter element is properly in stalled in the air filter case 6 Install l...

Page 81: ...e 4 1 l Fuel tank Refer to FUEL TANK on page 7 1 2 Check l Cylinder head breather hose 1 Cracks damage Replace Loose connection Connect properly CAUTION Make sure the cylinder head breather hose is routed correctly 3 Install l Fuel tank Refer to FUEL TANK on page 7 1 l Seat Refer to GENERAL CHASSIS on page 4 1 CHECKING THE EXHAUST SYSTEM 1 Check l Muffler 1 Cracks damage Replace l Exhaust pipe gas...

Page 82: ... min utes and then turn it off 4 Check l Coolant level NOTE Before checking the coolant level wait a few minutes until it settles CHECKING THE COOLING SYSTEM 1 Remove l Front panels l Seat Refer to GENERAL CHASSIS on page 4 1 l Fuel tank Refer to FUEL TANK on page 7 1 2 Check l Radiator 1 l Radiator inlet hose 2 l Radiator outlet hose 3 l Coolant reservoir hose 4 l Water pump breather hose 5 Crack...

Page 83: ... 6 Remove l Coolant reservoir 2 l Coolant reservoir cap 3 7 Drain l Coolant from the coolant reservoir 8 Install l Coolant reservoir 9 Connect l Coolant reservoir hose 10 Install l Coolant drain bolt along with the copper washer 11 Fill l Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special...

Page 84: ...aces immediately wash them with wa ter l Do not mix different types of antifreeze 12 Install l Radiator cap 13 Fill l Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install l Coolant reservoir cap 15 Install l Air filter case Refer to GENERAL CHASSIS on page 4 1 l Fuel tank Refer to FUEL TANK on page 7 1 16 Start the engine warm it up for several min utes and then s...

Page 85: ...he vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance CAUTION After adjusting the brake pedal position make sure there is no brake drag e Install the pin washer and cotter pin WARNING Always use a new cotter pin CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface NOTE l Place the vehicle o...

Page 86: ...ther 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 significantly lower the boiling point of ...

Page 87: ...peration is faulty NOTE l Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow l When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure l If bleedin...

Page 88: ...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 swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the v...

Page 89: ...s lubricant should be wiped with a clean cloth before riding NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check l Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so t...

Page 90: ...Finger tighten the upper ring nut 2 and then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install l Upper bracket Refer to STEERING HEAD on page 4 49 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING Securely suppo...

Page 91: ...e checked and regulated when the tyre temperature equals the ambient air temperature The tyre pressure must be adjusted accord ing to the total weight including cargo rid er passenger and accessories and the anticipated riding speed Operation of an overloaded vehicle could cause tyre damage an accident or an injury NEVER OVERLOAD THE VEHICLE After extensive tests the tires listed below have been a...

Page 92: ...ction of rotation mark 1 l Install the tyre with the mark pointing in the di rection of wheel rotation l Align the mark 2 with the valve installation point Rear tyre Size 100 80 17 M C 52P Manufacturer model MRF ZAPPER WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check l Outer cable Da...

Page 93: ...pedals LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Silicone grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap base...

Page 94: ...hing 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 with a cloth moistened with alcohol or lacquer thinner 5 Install Headlight bulb holder 6 Install Headlight bulb cover The following procedure applies to the high beam h...

Page 95: ...f 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 6 Install Headlight bulb holder 7 Connect Headlight coupler 8 Install Headlight bulb cover ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Headlight beam vertic...

Page 96: ...CALIPER 4 20 CHECKING THE FRONT BRAKE CALIPER 4 20 ASSEMBLING THE FRONT BRAKE CALIPER 4 21 INSTALLING THE FRONT BRAKE CALIPER 4 21 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 22 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 22 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 22 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 22 CHECKING THE REAR BRAKE DISC 4 30 REPLACING THE REAR BRAKES PADS 4 30 REMOVING TH...

Page 97: ...GS 4 48 REMOVING THE LOWER BRACKET 4 51 CHECKING THE STEERING HEAD 4 51 INSTALLING THE STEERING HEAD 4 51 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 CHECKING THE REAR SHOCKABSORBERASSEMBLY 4 54 CHECKING THE CONNECTINGARMAND RELAYARM 4 54 INSTALLING THE RELAY ARM 4 54 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 REMOVING THE SWINGARM 4 58 CHECKING THE SWINGARM 4 58 INSTALLING THE SWINGARM 4...

Page 98: ... side cover 1 8 Right rear side cover 1 9 Left side cover 1 10 Right side cover 1 11 Head Light 1 For installation reverse the removal proce dure GENERAL CHASSIS Removing the seat and covers T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m T R 26 Nm 2 6 m kg 19 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 5 2 4 6 7 8 9 10 1 2 3 3 11 ...

Page 99: ... 2 Air filter element 1 3 Air filter case joint clamp screw 1 Loosen 4 Air filter case 1 5 Cylinder head breather hose 1 Disconnect 6 Air induction system hose air filter case to 3 way joint 1 Disconnect 7 Air filter case silencer 1 For installation reverse the removal proce dure 1 2 4 7 6 5 3 T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 2 Nm 0 2 m lkg 1 4 ft Ib l GENERAL ...

Page 100: ...4 3 INSTALLING THE AIR FILTER CASE 1 Install l Air filter case joint clamp NOTE Align the projection a on the air filter case with the slot b in the air filter case joint clamp a b GENERAL CHASSIS ...

Page 101: ...ks 1 Speed sensor lead holder 1 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Brake disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m l kg 17 ft Ib l T R 60 Nm 6 0 m l kg 43 ft Ib l 2 5 3 4 6 7 LT LS LS 5 1 T R 7 Nm 0 7 m l kg 5 1 ft Ib l ...

Page 102: ...4 5 FRONT WHEEL Disassembling the front wheel Order Job Parts to remove Qty Remarks 1 Oil seal 1 2 Bearing 1 3 Spacer 1 4 Bearing 1 For assembly reverse the disassembly pro cedure 1 2 3 4 New LS ...

Page 103: ...the oil seal 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings with a bearing puller CHECKING THE FRONT WHEEL 1 Check l Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent wheel ax le 2 Check l Tyre l Front wheel Damage wear Replace Refer to...

Page 104: ... WHEEL STATIC BALANCE NOTE l After replacing the tyre wheel or both the front wheel static balance should be adjusted l Adjust the front wheel static balance with the brake discs installed 1 Remove l Balancing weight s 2 Find l Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X 1 mark at the bottom of the w...

Page 105: ...t 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 wheel is balanced 4 Check l Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it INSTALLING THE FRONT WHEEL DISC 1 I...

Page 106: ...ections meshed into the two slots respectively 6 Install l Front wheel NOTE Make sure the slot a in the outer tube fits over the stopper b on the speed sensor unit 7 Tighten l Wheel axle WARNING Make sure the brake hose is routed properly CAUTION Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smooth ly T R Wheel axle 60 Nm ...

Page 107: ...ssembly Order Job Parts to remove Qty Remarks 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Collar 1 5 Collar 1 6 Rear wheel 1 For installation reverse the removal proce dure LS 1 3 3 4 5 10 2 R 110 Nm 11 0 m l kg 80 ft Ib l T LS 6 ...

Page 108: ...Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Oil seal 1 4 Bearing 1 5 Rear wheel drive hub 1 6 Collar 1 7 Rear wheel drive hub damper 4 For installation reverse the removal proce dure 4 6 7 6 5 1 5 3 New LS LS 2 LT T R 18 Nm 1 8 m l kg 13 ft Ib l T R 43 Nm 4 3 m l kg 31 ft Ib l ...

Page 109: ...4 12 REAR WHEEL Disassembling the rear wheel Order Job Parts to remove Qty Remarks 1 Bearing 1 2 Spacer 1 3 Oil seal 1 4 Bearing 1 For assembly reverse the disassembly pro cedure LS 1 3 2 New 4 ...

Page 110: ...k Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tyre Rear wheel Damage wear Replace Refer to CHECKING THE TYRES on page 3 23 and CHECKING THE WHEELS on page 3 25 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks...

Page 111: ...wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 9 INSTALLING THE REAR WHEEL DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 33 3 Lubricate Rear wheel axle Contact surface of rear wheel hub and rear wh...

Page 112: ...the front brake calipers 1 Brake hose holder 1 2 Front brake caliper bolt 2 3 Front brake caliper 1 4 Brake pad clip 2 5 Brake pad pin 1 6 Front brake pad 2 7 Brake pad spring 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m l kg 5 1 ft Ib l T R 35 Nm 3 5 m l kg 25 ft Ib l 1 4 7 3 2 2 2 2 5 6 T R 6 Nm 0 6 m l kg 4 3 ft Ib l ...

Page 113: ...1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake light switch 1 5 Brake hose union bolt 1 6 Copper washer 2 7 Front brake hose 1 8 Brake Lever 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 For installation reverse the removal proce dure S T R 26 Nm 2 6 m kg 19 ft Ib T R 7 Nm 0 7 m kg 5 ft Ib New 5 4 7 6 9...

Page 114: ...the front brake master cylinder Order Job Parts to remove Qty Remarks 1 Dust boot 1 2 Circlip 1 3 Washer 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 3 4 5 New New ...

Page 115: ...get im mediate medical attention CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 4 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion ...

Page 116: ...Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level ...

Page 117: ... caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seals and dust seals CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery pas...

Page 118: ...G 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 si...

Page 119: ...heck Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir Cracks damage Replace Brake master cylinder reservoir diaphragm Damage wear Replace 4 Check Brake hose Cracks damage wear Replace ASSEMBL...

Page 120: ...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 master cylinder reser voir Water wi...

Page 121: ...4 24 FRONT BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 ...

Page 122: ... to remove Qty Remarks Rear wheel Refer to REAR WHEEL on page 4 10 1 Rear brake caliper 1 2 Brake pad retaining bolt 2 3 Rear brake pad 2 4 Brake pad spring 1 For installation reverse the removal proce dure T R 2 3 4 LT 1 T R 18 Nm 1 8 m kg 13 ft Ib 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 123: ...reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake light switch coupler 1 Disconnect 8 Rear brake master cylinder bolt 2 9 Rear brake master cylinder 1 10 Brake hose union bolt 1 11 Copper washer 2 12 Rear brake hose 1 For installation reverse the removal proce dure 8 9 8 11 12 T R 26 ...

Page 124: ...r brake master cylinder Order Job Parts to remove Qty Remarks 1 Brake hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 2 3 1 New New S T R 17 Nm 1 7 m kg 12 ft Ib New ...

Page 125: ...fer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 Rear wheel Refer to REAR WHEEL on page 4 10 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure 4 2 1 3 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib New ...

Page 126: ...ning bolt 2 2 Rear brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 1 6 Brake caliper piston dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly pro cedure 6 S BF 8 T R 6 Nm 0 6 m kg 4 2 ft Ib 2 New T R 18 Nm 1 8 m kg 13 ft Ib 5 4 1 3 ...

Page 127: ... WHEEL on page 4 12 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 18 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 1...

Page 128: ...the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 19 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system Brake pa...

Page 129: ...ake caliper pis ton b Remove the brake caliper piston seal and dust seal CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow ...

Page 130: ...in the brake caliper 2 Install Brake pad spring Brake pads Brake pad retaining bolts Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4 30 3 Install Rear wheel Refer to REAR WHEEL on page 4 10 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorat...

Page 131: ...ke master cylinder 4 Remove Rear brake light switch 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 ...

Page 132: ...sult in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to B...

Page 133: ... holder 1 9 Right grip end 1 10 Right handlebar switch 1 11 Throttle cable 1 Disconnect 12 Throttle grip 1 13 Front brake light switch 1 14 Front brake master cylinder holder 1 15 Front brake master cylinder 1 16 Plug 2 2 1 3 4 5 6 7 8 9 11 12 13 14 4 20 19 16 17 18 17 16 18 10 10 15 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib LS LS LS LS LS T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m k...

Page 134: ...he removal proce dure Removing the handlebars Order Job Parts to remove Qty Remarks 2 1 3 4 5 6 7 8 9 11 12 13 14 4 20 19 16 17 18 17 16 18 10 10 15 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib LS LS LS LS LS T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 0 ft Ib T R 7 Nm 0 7 m kg 5 0 ft Ib T R 7 Nm 0 7 m kg 5 0 ft Ib ...

Page 135: ...g forward Align the mating surfaces of the brake master cylinder holder with the punch mark b on the handlebar First tighten the front bolt then the rear bolt 3 Install Front brake light switch NOTE Before fully installing the front brake light switch be sure to completely install the rubber cover over the switch Also be sure not to twist the front brake light switch lead when screwing in the swit...

Page 136: ... the clutch cable with a thin coat of lithium soap based grease 9 Install Left handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole b in the left handlebar 10 Connect Clutch switch coupler 11 Install Handlebar grip 1 Left grip end 2 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of the left hand...

Page 137: ...hrottle cable clutch cable and handlebar switch leads are routed properly 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 11 14 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 6 Clutch lever free play 10 0 15 0 mm Throttle cable free play 3 0 5 0 mm sssssssssssssssssssssssssssssssssssssss ...

Page 138: ... FRONT WHEEL on page 4 6 1 Front fender 1 2 Plug 1 3 Handlebar bolt 1 Loosen 4 Handlebar pinch bolt 1 Loosen 5 Upper bracket pinch bolt 1 Loosen 6 Lower bracket pinch bolt 1 Loosen 7 Front fork leg 1 For installation reverse the removal proce dure 1 6 7 2 3 5 4 4 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LT T R 28 Nm 2 8 m kg 20 ft Ib ...

Page 139: ...ork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Washer 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil flow stopper 1 14 Oil seal 1 1 12 9 8 6 7 14 2 3 4 5 10 15 11 13 New New New New New LT T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib ...

Page 140: ...For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Qty Remarks 1 12 9 8 6 7 14 2 3 4 5 10 15 11 13 New New New New New LT T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib ...

Page 141: ...olt 4 WARNING Before loosening the upper and lower brack et pinch bolts support the front fork leg 3 Remove Front fork leg DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Rubber cap Clip 1 Front fork cap 2 with O ring Fork spring 2 1 3 4 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust sea...

Page 142: ... assembling the front fork leg do not allow any foreign mate rial to enter the front fork ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts...

Page 143: ...the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation Recommended oil Fork oil 10W or equivalent T R Damper rod bolt 28 Nm 2 8 m kg 20 ...

Page 144: ...fork 9 After filling the front fork leg slowly stroke the inner tube 1 up and down at least ten times to distribute the fork oil NOTE Be sure to stroke the inner tube slowly because the fork oil may spurt out 10 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 11 Measure Fr...

Page 145: ...ALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts 2 Tighten Lower bracket pinch bolt 1 Upper bracket pinch bolt 2 Handlebar bolt 3 Handlebar pinch bolt 4 WARNING Make sure the brake hose clutch cable and leads are routed properly 1 a New New T R Lower bracket pinch bolt 28 N...

Page 146: ...rake pipe bracket 1 2 Steering stem bolt 1 3 Upper bracket 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Lower bracket 1 9 Bearing cover 1 10 Upper bearing inner race 1 11 Upper bearing 1 12 Lower bearing 1 2 3 4 5 6 7 9 10 11 13 14 15 8 16 12 1 New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 48 Nm 4 8 m kg 35 ft lb 2nd 13 Nm 1 3 m kg 9 4 ft lb LS LS T R 35 Nm 3 5 m kg 25 ft ...

Page 147: ...st seal 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Qty Remarks 2 3 4 5 6 7 9 10 11 13 14 15 8 16 12 1 New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 48 Nm 4 8 m kg 35 ft lb 2nd 13 Nm 1 3 m kg 9 4 ft lb LS LS T R 7 Nm 0 7 m kg 5 0 ft Ib T R 35 Nm 3 5 m kg 25 ft lb ...

Page 148: ... long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es CAUTION If the bearing races are not installed proper ly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check Upper bracket Lo...

Page 149: ...n page 3 21 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 41 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem bolt 35 Nm 3 5 m kg 25 ft lb ...

Page 150: ...lower nut bolt 1 1 4 Relay arm nut bolt 1 1 5 Relay arm 1 6 Rear shock absorber assembly upper nut bolt 1 1 7 Rear shock absorber assembly 1 8 Spacer 3 9 Oil seal 6 10 Bearing 3 For installation reverse the removal proce dure T R 44 Nm 4 4 m l kg 32 ft Ib l T R 44 Nm 4 4 m l kg 32 ft Ib l LS LS LS LS LS LS LS 8 9 6 6 4 5 10 10 10 9 9 9 2 9 8 8 1 2 1 7 3 3 4 1 LS LS T R 44 Nm 4 4 m l kg 32 ft Ib l ...

Page 151: ...e rear shock ab sorber assembly Bolts Bends damage wear Replace CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arms Relay arm Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Spacers Damage scratches Replace INSTALLING THE RELAY ARM 1 Lubricate Spacers Bearings 2 Install Bearing 1 to the relay arm Oil seal 2 to the relay arm INSTALLING THE REAR SHOCK ABSO...

Page 152: ...onnecting arm with its chamfered side facing outward 4 Tighten Connecting arm nuts 2 Connecting arm 3 Rear shock absorber assembly 4 Swingarm 5 Frame T R Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 32 ft lb T R Relay arm nut 44 Nm 4 4 m kg 32 ft lb T R Rear shock absorber assembly lower nut 44 Nm 4 4 m kg 32 ft lb T R Connecting arm nut 44 Nm 4 4 m kg 32 ft lb 5 1 2 3 4 ...

Page 153: ... 10 Relay arm Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBL Y on page 4 53 1 Drive chain cover 1 2 Pivot shaft nut 1 3 Pivot shaft 1 4 Swingarm 1 5 Dust Cover 2 6 Drive chain guide 1 7 Spacer 1 8 Oil seal 2 9 Bearing 1 10 Spacer 2 3 4 6 5 9 1 2 8 11 10 5 7 11 T R 70 Nm 7 0 m kg 50 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib New 8 New New LS LS LS LS LS LS ...

Page 154: ...2 For installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Qty Remarks 3 4 6 5 9 1 2 8 11 10 5 7 11 T R 70 Nm 7 0 m kg 50 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib New 8 New New LS LS LS LS LS LS ...

Page 155: ...eck 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 shaft 3 Wash Pivot shaft Dust covers Spacers Bearings 4 Check Dust covers Spacers Oil seals Damage wear Replace Bearings Damage pitting Replace INSTALLING THE SWINGARM 1 Lubricate Bearings Spacers Dust covers Pivot shaft 2 Install Beari...

Page 156: ...ay arm Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 48 and REAR WHEEL on page 4 10 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 20 2 Swingarm A Left side B Right side Drive chain slack 20 40 mm a a 1 2 1 A B a ...

Page 157: ...Rear wheel Refer to REAR WHEEL on page 4 10 Swingarm Refer to SWINGARM on page 4 56 1 Drive sprocket cover 1 2 Drive sprocket retainer 1 4 Drive chain 1 3 Drive sprocket 1 For installation reverse the removal proce dure 3 2 4 1 T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l ...

Page 158: ...chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain 4 Check Drive chain rollers 1 Damage wear Replace the drive chain Drive chain side plates 2 Damage wear Replace the drive chain Cracks Replace the drive chain 5 Lubricate Drive chain 15 link length limit 190 5 mm Recommended lubricant Cha...

Page 159: ...ge 4 10 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 20 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 swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubricant chain lubricant suitable for O ring chains T R Drive sp...

Page 160: ...5 14 CHECKING THE ROCKERARMSAND ROCKERARM SHAFTS 5 14 INSTALLING THE CAMSHAFTAND ROCKERARMS 5 15 5 16 REMOVING THE VALVES 5 17 CHECKING THE VALVES AND VALVE GUIDES 5 17 CHECKING THE VALVE SEATS 5 18 CHECKING THE VALVE SPRINGS 5 19 INSTALLING THE VALVES 5 20 5 22 REMOVING THE PISTON 5 23 CHECKING THE CYLINDER AND PISTON 5 23 CHECKING THE PISTON RINGS 5 24 CHECKING THE PISTON PIN 5 25 INSTALLING THE...

Page 161: ...ECKING THE OILPUMP 5 47 ASSEMBLING THE OIL PUMP 5 47 INSTALLING THE OIL PUMP 5 48 5 49 CHECKING THE SHIFT SHAFT 5 50 CHECKING THE STOPPER LEVER 5 50 INSTALLING THE SHIFT SHAFT 5 50 5 51 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 5 53 CHECKING THE BALANCER GEARS AND PRIMARY DRIVE GEAR 5 53 ASSENBLING THE BALANCER DRIVEN GEAR 5 53 INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 5 53 5 5...

Page 162: ...HAFT 5 61 INSTALLING THE CRANKSHAFT 5 61 5 63 CHECKING THE SHIFT FORKS 5 66 CHECKING THE SHIFT DRUM ASSEMBLY 5 66 CHECKING THE TRANSMISSION 5 66 CHECKING THE CLUTCH PUSH RODS 5 67 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 67 INSTALLING THE SHIFT FORKSAND SHIFT DRUMASSEMBLY 5 67 ...

Page 163: ... Order Job Parts to remove Qty Remarks 1 Muffler end cap 1 2 Muffler protector 1 3 Muffler 1 4 Exhaust pipe gasket 1 For installation reverse the removal proce dure 4 3 2 1 T R 20 Nm 2 0 m kg 14 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib ...

Page 164: ...page 3 14 Seat Side panel Front panel Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body Intake manifold Refer to THROTTLE BODY on page 7 4 Water pump breather hose Radiator outlet hose Radiator inlet hose Radiator Refer to RADIATOR on page 6 1 Air cut off valve Reed valve Plate Refer to AIR INDUCTION SYSTEM on page 7 9 Drive sprocket cover ...

Page 165: ...onnector 1 Disconnect 5 Starter motor lead 1 Disconnect 6 Clutch cable 1 Disconnect 7 Negative battery lead 1 Disconnect 8 Shift arm 1 For installation reverse the removal proce dure Disconnecting the leads and couplers Order Job Parts to remove Qty Remarks 1 3 2 3 7 4 5 8 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 6 T R 9 Nm 0 9 m kg 6 5 ft Ib ...

Page 166: ...ble stand under the engine 1 Engine mounting bolt nut front side 1 1 2 Engine mounting bolt nut rear lower side 1 1 3 Engine mounting bolt nut rear upper side 1 1 4 Engine 1 For installation reverse the removal proce dure 2 3 3 4 1 1 2 T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib E E E ...

Page 167: ...ut front side 7 NOTE Do not fully tighten the bolts and nuts 2 Tighten Engine mounting nut rear upper side Engine mounting nut rear lower side Engine mounting nut front side INSTALLING THE SHIFT ARM 1 Install Shift arm 1 T R Engine mounting nut rear upper side 49 Nm 4 9 m kg 35 ft lb T R Engine mounting nut rear lower side 49 Nm 4 9 m kg 35 ft lb T R Engine mounting nut front side 49 Nm 4 9 m kg 3...

Page 168: ...4 Water pump Refer to WATER PUMP on page 6 6 Radiator Refer to RADIATOR on page 6 1 Muffler Refer to ENGINE REMOVAL on page 5 1 Clutch cable Disconnect Refer to CLUTCH on page 5 36 1 Spark plug cap 1 Disconnect 2 Spark plug 1 3 Crankshaft end accessing screw 1 4 Timing mark accessing screw 1 5 Engine mounting bolt nut front side 1 1 New New New New New New New E E E 4 12 11 14 15 16 15 13 8 7 1 2 ...

Page 169: ...wel pin 2 16 Timing chain guide exhaust side 1 For installation reverse the removal proce dure Removing the cylinder head Order Job Parts to remove Qty Remarks New New New New New New New E E E 4 12 11 14 15 16 15 13 8 7 1 2 6 4 4 10 9 5 4 3 5 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 49 Nm 4 ...

Page 170: ...loosen the camshaft sprocket bolt 3 Remove Camshaft sprocket NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 1 4 Remove Cylinder head NOTE Loosen the bolts in the proper sequence as shown Loosen each bolt 1 2 of a turn at a time After all of the bolts are fully loosened remove them CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with...

Page 171: ...re than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set 2 Check Timing chain guide exhaust side Damage wear Replace CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner ...

Page 172: ...ssion cam does not project from the camshaft exhaust cam as shown in the illustration B INSTALLING THE CYLINDER HEAD 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 2 Tighten Cylinder head bolts 1 Cylinder head bolts 2 NOTE Lubricate the cylinder head bolts with engine oil Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them ...

Page 173: ...the tensioner rod ful ly clockwise with a thin screwdriver 1 b With the timing chain tensioner rod turned all the way into the timing chain tensioner hous ing with the thin screwdriver still installed in stall the gasket and the timing chain tensioner 2 onto the cylinder block c Tighten the timing chain tensioner bolts 3 to the specified torque d Remove the screwdriver make sure the tim ing chain ...

Page 174: ... camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 T R Camshaft sprocket bolt 30 Nm 3 0 m kg 22 ft lb d c ...

Page 175: ...ad Refer to CYLINDER HEAD on page 5 6 1 Locknut 2 2 Adjusting screw 2 3 Camshaft retainer 1 4 Camshaft 1 5 Rocker arm shaft 2 6 Intake rocker arm 1 7 Exhaust rocker arm 1 For installation reverse the removal proce dure M M M M 1 2 5 5 4 3 1 2 6 New E E E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 7 ...

Page 176: ...shaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Check Camshaft oil passage Obstruction Blow out with compressed air CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Damage wear Replace 2 1 1 2 Camshaft lobe dimensions Intake a 25 177 0 05 mm Limit 25 027 mm ...

Page 177: ...D ROCKER ARMS 1 Lubricate Rocker arms Rocker arm shafts 2 Lubricate Camshaft 3 Install Intake and exhaust rocker arms Rocker arm shafts 1 NOTE Make sure that the cutout a in each rocker arm shaft is facing downward as shown in the illustration Make sure the rocker arm shafts intake and exhaust are completely pushed into the cylin der head Rocker arm inside diameter 9 985 10 000 mm Limit 10 030 mm ...

Page 178: ...LINDER HEAD on page 5 6 Rocker arms Camshaft Refer to CAMSHAFT on page 5 13 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure New New New New M M M M M M M 1 2 3 6 7 8 1 2 3 6 7 8 1 2 3 6 7 8 1 2 3 6 7 8 4 4 5 5 ...

Page 179: ...ring with the valve spring compressor and the valve spring compressor attachment 2 Valve spring compressor YSST 603 2 1 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place ssssssssssssssssssssssssss ssssssssssssssssssssssssss CHECKING THE VALVES AND VALVE...

Page 180: ... or replaced always re place the valve stem seal Valve stem runout 0 010 mm CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Install the valve into the cy...

Page 181: ...ound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve sp...

Page 182: ... Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Lower spring seat 1 Free length intake 41 71 mm Limit 39 62 mm Free length exhaust 41 71 mm Limit 39 62 mm Installed compression spring force intake 140 162 N 31 47 36 42 lbf 14 28 16 52 kgf Installed compression spring force exhaust 140 162 N 31 47 36 42 lbf 14 28 16 52 kgf Installed length intake 35 30 mm Installed length e...

Page 183: ...springs with the larger pitch a facing up 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor YSST 603 New 1 ...

Page 184: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 6 1 Cylinder 1 2 Cylinder gasket 1 3 Dowel pin 2 4 Piston pin circlip 2 5 Piston pin 1 6 Piston 1 8 2nd ring 1 For installation reverse the removal proce dure E E E E New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib 6 5 4 7 8 4 2 3 1 3 9 9 Oil Ring 1 7 Top Ring 1 ...

Page 185: ...Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace 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 186: ...s as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown C maximum of D1 2 D T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 b 5 0 mm 0 20 in from the bottom edge of th...

Page 187: ... pin bore clearance Out of specification Replace the piston pin and piston as a set INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Oil ring expander 3 Lower oil ring rail 4 Upper oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer marks or numbers face up Piston ring Top ring End gap installed 0 10 0 25 mm Limit 0 40 mm 2nd ring End gap installed 0...

Page 188: ...e 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder head gasket Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil New 3 2 1 a New a T op rin...

Page 189: ...2 Crankshaft position sensor coupler 1 Disconnect 3 Neutral switch lead connector 1 Disconnect 4 Timing mark accessing screw 1 5 Crankshaft end accessing screw 1 6 Magneto cover 1 7 r cover gasket 1 Magneto 8 Dowel pin 2 9 Crankshaft position sensor 1 10 Stator coil 1 11 rotor 1 Magneto LS LS E E T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 14 Nm 1 4 m l kg 10 ft Ib l T R ...

Page 190: ... clutch assembly 1 For installation reverse the removal proce dure Order Job Parts to remove Qty Remarks Removing the magneto and starter clutch LS LS E E T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 14 Nm 1 4 m l kg 10 ft Ib l T R 70 Nm 7 0 m l kg 50 ft lb l T R 10 Nm 1 0 m l kg 7 2 ft Ib l LT LT E E E 20 11 14 15 New New New New New 17 13 19 18 16 12 3 1 2 9 10 7 4 5 8 8...

Page 191: ...t center bolt and the crank shaft NOTE Make sure the magneto puller is centered over the magneto rotor 1 Remove Starter clutch bolts 1 NOTE While holding the magneto rotor with the magneto holder remove the Starter clutch CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Starter clutch spring caps 2 Starter clutch springs 3 Damage wear Replace the starter clutch assembly Magneto puller ...

Page 192: ...clockwise B it should turn freely otherwise the starter clutch is faulty and must be re placed INSTALLING THE STARTER CLUTCH 1 Install Starter clutch assembly Starter clutch bolts 1 NOTE While holding the magneto rotor tighten the bolts 1 Stake the end a of each starter clutch bolt INSTALLING THE MAGNETO 1 Install Woodruff key Magneto rotor Washer Magneto rotor nut NOTE Clean the tapered portion o...

Page 193: ...lant onto the crankshaft position sensor stator assembly lead grommet 4 Install Magneto cover NOTE Tighten the magneto cover bolts in the proper tightening sequence as shown Yamaha bond No 1215 TG 1215 T R Magneto cover bolt 10 Nm 1 0 m kg 7 2 ft lb 1 2 2 10 3 11 4 5 1 6 7 8 9 the magneto rotor LS ...

Page 194: ...ER ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Qty Remarks 1 Starter motor 1 2 Starter motor lead 1 Disconnect For installation reverse the removal proce dure 1 2 T R 10 Nm 1 0 m l kg 7 2 ft Ib l ...

Page 195: ...tor Order Job Parts to remove Qty Remarks 1 O ring 1 2 Starter motor yoke 1 3 O ring 1 4 Commutator 1 5 Starter motor front cover brush holder set 1 6 Brush 2 7 Brush spring 2 For assembly reverse the disassembly pro cedure New New LS 4 2 5 1 6 7 7 6 3 ...

Page 196: ...blade that has been grounded to fit the commutator NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Armature assembly resistances commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the multimeter b If any resistance is out of specification re place the starter motor 5 Measu...

Page 197: ... 8 Check Bearing Oil seal Damage wear Replace the starter motor front cover brush holder set ASSEMBLING THE STARTER MOTOR 1 Install Starter motor front cover brush holder set 1 Starter motor yoke 2 NOTE Align the marks a on the starter motor yoke and starter motor front cover brush holder set made during disassembly Brush spring force 3 92 5 88 N a 1 2 ...

Page 198: ...INE OIL on page 3 10 1 Clutch cable 1 Disconnect 3 Oil filter cover 1 4 Oil filter 1 6 Clutch cover 1 7 Clutch cover gasket 1 5 Dowel pin 2 For installation reverse the removal proce dure 1 T R 9 Nm 0 9 m kg 6 5 ft Ib LS New 2 New New LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 6 5 8 7 3 6 4 4 E 2 Oil seal 2 ...

Page 199: ... Friction plate 1 3 8 Clutch plate 4 9 Friction plate 2 1 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 14 Lock washer 1 15 Clutch boss 1 16 Thrust washer 1 17 Clutch housing 1 New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 70 Nm 7 0 m kg 50 ft lb E E 9 4 4 8 7 8 8 7 8 7 E 6 4 5 3 2 1 10 11 12 13 14 15 16 17 18 ...

Page 200: ...llation reverse the removal proce dure Removing the clutch Order Job Parts to remove Qty Remarks New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 70 Nm 7 0 m kg 50 ft lb E E 9 4 4 8 7 8 8 7 8 7 E 6 4 5 3 2 1 10 11 12 13 14 15 16 17 18 ...

Page 201: ...der Job Parts to remove Qty Remarks Clutch housing Refer to CLUTCH on page 5 36 1 Clutch push lever 1 2 Clutch push lever spring 1 3 Circlip 1 4 Oil seal 1 5 Bearing 1 For installation reverse the removal proce dure New New LS E E 1 2 3 4 5 ...

Page 202: ...ess Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Clutch hub holder YSST 733 Friction plate 1 thickness 2 90 3 10 mm Wear limit 2 80 mm Friction plate 2 thickness 2 90 3 10 mm Wear limit 2 80 mm A B 2 1 3 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch pl...

Page 203: ...on 2 Check Bearing Damage wear Replace the bearing and clutch housing CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch operation CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace CHECKING THE CLUTCH PUSH LEVER AND SHORT CLUTCH PUSH ROD 1 Check Clutch push lever ...

Page 204: ...STALLING THE CLUTCH 1 Install Conical spring washer 1 NOTE Install the conical spring washer as shown in the illustration 2 Install Clutch housing Thrust washer 1 NOTE Be sure the thrust washer sharp edged conner a is positioned opposite side to the clutch boss 3 Install Clutch boss 1 Lock washer 2 Clutch boss nut NOTE Lubricate the clutch boss nut threads and lock washer mating surfaces with engi...

Page 205: ...s pattern 9 Adjust Clutch mechanism free play a Check that projection a on the clutch push lever 1 aligns with mark b shown on the crankcase in the illustration by pushing the clutch push lever manually in direction c un til it stops b If projection a is not aligned with mark b align them as follows Loosen the locknut 2 With the clutch push lever fully pushed in di rection c turn the short clutch ...

Page 206: ...THE CLUTCH CABLE FREE PLAY on page 3 11 10 Install Oil seal 1 Oil seal 2 11 Install Clutch cover NOTE Tighten the clutch cover bolts in the proper tight ening sequence as shown T R Clutch cover bolt 10 Nm 1 0 m kg 7 2 ft lb 1 a 2 b 11 2 12 10 9 9 6 8 1 7 3 13 6 5 4 ...

Page 207: ... CLUTCH on page 5 36 Primary drive gear Balancer drive gear Refer to BALANCER GEAR on page 5 51 1 Oil baffle plate 1 2 Oil pump assembly 1 3 Oil pump drive gear 1 For installation reverse the removal proce dure T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT 2 3 1 5 45 OIL PUMP ...

Page 208: ...pump Order Job Parts to remove Qty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump driven gear 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Oil pump housing 1 For assembly reverse the disassembly pro cedure 1 5 2 4 6 3 E E ...

Page 209: ...defective part s EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Oil pump inner rotor Oil pump outer rotor Oil pump driven gear with the recommended lubricant 2 Install Oil pump outer rotor Oil pump inner rotor 1 Oil pump driven gear Pin 2 NOTE When installing the inner rotor align the pin 2 in the oil pump shaft with the groove a in the in ner rotor 1 1 Inner rotor 2 Outer rotor 3 Oil pump housing R...

Page 210: ...eration Refer to CHECKING THE OIL PUMP on page 5 45 INSTALLING THE OIL PUMP 1 Install Oil pump assembly CAUTION After tightening the screws make sure the oil pump turns smoothly T R Oil pump assembly screw 4 Nm 0 4 m kg 2 4 ft lb 2 a 1 ...

Page 211: ...ts to remove Qty Remarks Clutch housing Refer to CLUTCH on page 5 36 Shift arm 1 Shift shaft 1 2 Circlip 1 3 Shift shaft spring 1 4 Stopper lever 1 5 Stopper lever spring 1 6 Oil seal 1 For installation reverse the removal proce dure LT T R 10 Nm 1 0 m kg 7 2 ft Ib 5 1 3 6 4 2 New E LS ...

Page 212: ...ly Replace the stopper lever Stopper lever spring Damage wear Replace INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 NOTE Hook the end of the shift shaft spring onto the shift shaft spring st...

Page 213: ... gear nut 1 2 Balancer driven gear nut 1 3 Washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Straight key 1 7 Lock washer 1 8 Balancer driven gear plate 1 1 9 Balancer driven gear 1 10 Buffer boss 1 11 Spring 4 12 Dowel pin 2 13 Straight key 1 14 Balancer driven gear plate 2 1 1 3 4 5 6 14 15 9 10 11 8 7 2 T R 50 Nm 5 0 m kg 36 ft Ib New 13 12 T R 60 Nm 6 0 m kg 43 ft Ib E ...

Page 214: ...or installation reverse the removal proce dure Removing the primary drive gear and balancer gears Order Job Parts to remove Qty Remarks 1 3 4 5 6 14 15 9 10 11 8 7 2 T R 50 Nm 5 0 m kg 36 ft Ib New 13 12 T R 60 Nm 6 0 m kg 43 ft Ib E ...

Page 215: ...ing Dowel pin Cracks damage wear Replace 2 Check Primary drive gear Refer to CHECKING THE PRIMARY DRIVE GEAR on page 5 42 ASSEMBLING THE BALANCER DRIVEN GEAR 1 Assemble Dowel pins 1 Springs 2 to the buffer boss NOTE Install the dowel pins and springs alternately as shown as 2 Assemble Buffer boss 1 Balancer driven gear 2 NOTE Align the punch mark a in the buffer boss with the punch mark b in the b...

Page 216: ...en balanc er drive gear 3 and balancer driven gear 4 and then tighten the balancer driven gear nut Place the aluminum plate b between balanc er drive gear 3 and balancer driven gear 4 and then tighten the primary drive gear nut 3 Bend the lock washer tab along a flat side of the nut T R Balancer driven gear nut 50 Nm 5 0 m kg 36 ft lb Primary drive gear nut 60 Nm 6 0 m kg 43 ft lb b a 2 1 c 3 a 4 ...

Page 217: ...haft Refer to SHIFT SHAFT on page 5 53 Starter motor Refer to ELECTRIC STARTER on page 5 32 Balancer gears Refer to BALANCER GEAR on page 5 51 Magneto rotor Refer to MAGNETOAND STARTER CLUTCH on page 5 27 1 Timing chain guide intake side 1 2 Chain cover 1 3 Timing chain 1 4 Engine oil drain plug 1 New New T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 ...

Page 218: ...e 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Qty Remarks New New T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 3 2 4 5 6 7 9 9 8 10 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib LS ...

Page 219: ...rks Crankshaft Balancer Refer to CRANKSHAFT on page 5 60 Transmission Refer to TRANSMISSION on page 5 64 1 Oil seal 1 2 Bearing retainer 1 3 Bearing 7 For installation reverse the removal proce dure LT E E E 2 1 3 3 3 3 3 3 3 T R 7 Nm 0 7 m kg 5 1 ft Ib LS 5 57 CRANKCASE ...

Page 220: ...rankcase halves sepa rate evenly CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain...

Page 221: ...w any sealant to come into contact with the oil gallery 3 Install Right crankcase NOTE Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment teeth will not contact the crank case during crankcase installation 4 Install Crankcase bolts NOTE Tighten each bolt 1 4 of a turn at a time in stag es and in the proper sequence as shown M6 70 mm 7 9 ...

Page 222: ...FT Removing the crankshaft and balancer Order Job Parts to remove Qty Remarks Crankcase Separate Refer to CRANKCASE on page 5 55 1 Balancer 1 2 Crankshaft 1 For installation reverse the removal proce dure New New 1 2 LS LS E E ...

Page 223: ...place the crank shaft bearing or both NOTE Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification Replace the crank shaft 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket Damage wear Replace the crankshaft Bearing Cracks damage wear Replace the crank shaft 5 Check Crankshaft journal Scratches wear Replace the crankshaft C...

Page 224: ...lips with lithium soap based grease and each bearing with engine oil NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft bot toms against the bearing 1 5 62 CRANKSHAFT ...

Page 225: ...ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Shift fork guide bar 1 2 Spring 2 3 Shift drum assembly 1 4 Shift fork R 1 5 Shift fork C 1 6 Shift fork L 1 7 Drive axle assembly 1 8 Main axle assembly 1 9 Long clutch push rod 1 For installation reverse the removal proce dure E 7 8 9 2 1 2 3 4 5 6 E E E E ...

Page 226: ...der Job Parts to remove Qty Remarks 1 2nd pinion gear 1 2 6th pinion gear 1 3 3rd 4th pinion gear 1 4 Circlip 1 5 T oothed washer 1 6 5th pinion gear 1 7 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure M 2 1 4 5 3 6 7 M M ...

Page 227: ...rks 1 Washer 1 2 2nd wheel gear 1 3 6th wheel gear 1 4 Washer 1 5 1st wheel gear 1 6 Spacer 1 7 5th wheel gear 1 8 Circlip 1 9 T oothed washer 1 10 4th wheel gear 1 11 3rd wheel gear 1 12 Drive axle 1 For assembly reverse the disassembly pro cedure 2 1 9 10 7 5 6 11 8 4 12 3 M M M M ...

Page 228: ...vement Replace the shift forks and shift fork guide bar as a set CHECKING THE SHIFT DRUM ASSEMBLY 1 Check l Shift drum groove Damage scratches wear Replace the shift drum assembly l Shift drum segment 1 Damage wear Replace the shift drum as sembly l Shift drum bearing 2 Damage pitting Replace the shift drum as sembly CHECKING THE TRANSMISSION 1 Measure l Main axle runout with a centering device an...

Page 229: ... Measure l Push rod bending limit Out of specification Replace the long clutch push rod ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install l Toothed washer 1 l Circlip 2 NOTE Be sure to install the circlip so that its sharp edge a is facing away from the toothed wash er and gear l Be sure the circlip ends b are positioned at the axle spline groove c 2 Install l 2nd pinion gear 1 NOTE Press the 2nd ...

Page 230: ...ght side of the engine and be in the following sequence R C L 2 Check l Transmission Rough movement Repair NOTE l Apply engine oil to each gear and bearing thor oughly l Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 1 2 3 5 4 ...

Page 231: ...IATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 8 CHECKING THE WATER PUMP 6 8 ASSEMBLING THE WATER PUMP 6 8 INSTALLING THE WATER PUMP 6 9 ...

Page 232: ... to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir 1 5 Radiator fan coupler 1 Disconnect 6 Water pump breather hose 1 7 Radiator outlet hose 1 8 Radiator inlet hose 1 9 Radiator cap 1 12 5 9 8 2 1 3 4 11 7 6 10 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 f...

Page 233: ...diator cover 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Qty Remarks 12 5 9 8 2 1 3 4 11 7 6 10 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 8 Nm 0 8 m kg 5 8 ft Ib RADIATOR ...

Page 234: ... specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 14 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Rad...

Page 235: ...anel Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Radiator inlet hose 1 2 Coolant temperature sensor coupler 1 Disconnect 3 Coolant temperature sensor 1 4 Thermostat cover 1 5 Thermostat 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New 2 3 1 4 5 THERMOSTAT ...

Page 236: ...RMOSTAT 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Install Copper washer Coolant temperature sensor CAUTION Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 14 4...

Page 237: ...er to GENERAL CHASSIS on page 4 1 Clutch cable engine side Disconnect Refer to CLUTCH on page 5 37 Coolant Drain Refer to CHANGING THE COOLANT on page 3 14 1 Radiator outlet hose 1 2 Water pump breather hose 1 3 Cylinder head breather hose 1 Disconnect 4 Radiator bracket bolt 1 5 Water pump assembly 1 For installation reverse the removal proce dure New New 2 5 3 1 4 T R 10 Nm 1 0 m kg 7 2 ft Ib LS...

Page 238: ...er gasket 1 4 Impeller shaft retainer 1 5 Impeller shaft 1 6 Water pump housing plate 1 7 Water pump housing gasket 1 8 Water pump seal 1 9 Bearing 1 10 Water pump housing 1 For assembly reverse the disassembly pro cedure New New New LS T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 m l kg 7 2 ft Ib l 1 2 3 10 8 5 9 4 6 7 LT ...

Page 239: ...r pump seal with the special tools Install the water pump seal with the special tools to the specified depth as shown in the il lustration 2 Lubricate Water pump seal lip 3 Install Water pump housing gasket 1 Water pump housing plate 2 Impeller shaft Impeller shaft retainer 3 NOTE Before installing the impeller shaft retainer lu bricate the slit on impeller shaft end with a thin coat of lithium so...

Page 240: ... the projection a on the impeller shaft with the slit b on the camshaft sprocket bolt Lubricate the O rings with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 14 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pres...

Page 241: ...EL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 2 7 4 REMOVING THE THROTTLE BODY 7 6 CHECKING THE FUEL INJECTOR 7 6 CHECKING THE THROTTLE BODY 7 6 CHECKING THE FUEL PRESSURE 7 6 INSTALLING THE THROTTLE BODY 7 6 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 12 ...

Page 242: ...ASSIS on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Fuel tank 1 Disconnect 4 Fuel pump retainer 1 5 Fuel pump 1 6 Fuel pump gasket 1 For installation reverse the removal proce dure 3 6 5 4 6 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib New T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 243: ...E FUEL PUMP 1 Remove Fuel pump CAUTION Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly INSTALLING THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a...

Page 244: ...7 3 FUEL TANK To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 ...

Page 245: ...nnect 3 Fuel injector 1 4 Fuel injector gasket 1 5 FID fast idle solenoid coupler 1 Disconnect 6 Throttle body sensor assembly coupler 1 Disconnect 7 Throttle cable 1 Disconnect 8 Throttle body joint clamp screw 2 Loosen 9 Throttle body 1 CAUTION The throttle body should not be disas sembled LT LT LT T R 10 Nm 1 0 m l kg 7 2 ft Ib l LS E 3 T R 12 Nm 1 2 m l kg 8 7 ft Ib l 2 6 1 9 8 5 8 10 7 11 12 ...

Page 246: ...ect 12 Intake manifold 1 For installation reverse the removal proce dure Removing the throttle body Order Job Parts to remove Qty Remarks LT LT LT T R 10 Nm 1 0 m l kg 7 2 ft Ib l LS E 3 T R 12 Nm 1 2 m l kg 8 7 ft Ib l 2 6 1 9 8 5 8 10 7 11 12 New New 4 T R 2 Nm 0 2 m l kg 1 4 ft Ib l ...

Page 247: ... 4 1 b Lift the front of the fuel tank c Disconnect the fuel hose 1 from the fuel pump 2 WARNING Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses d Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel pump 2 e Connect the pressure gauge 4 to fuel pres sure adapter 3 f Start t...

Page 248: ... the throttle body joint with the slot b in the intake manifold 3 Install Throttle body NOTE Align the projection a on the throttle body with the slot b throttle body joint 4 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 6 b a b a b a ...

Page 249: ...7 8 THROTTLE BODY ...

Page 250: ...7 9 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 2 5 4 5 6 3 2 1 6 4 3 ...

Page 251: ...nator 2 Air induction system hose 3 way joint to resonator 3 Air induction system hose 3 way joint to air cut off valve 4 Air induction system hose air filter case to 3 way joint 5 Air induction system vacuum hose 6 Air cut off valve ...

Page 252: ...uction system hose 3 way joint to reso nator 1 2 Resonator 1 3 Air induction system hose air filter case to 3 way joint 1 4 Air induction system hose 3 way joint to air cut off valve 1 5 Air induction system vacuum hose 1 6 Air cut off valve 1 7 Reed valve assembly 1 8 Reed valve plate 1 For installation reverse the removal proce dure 1 2 3 6 7 8 4 5 T R 10 Nm 1 0 m l kg 7 2 ft Ib l T R 10 Nm 1 0 ...

Page 253: ...speeds and when the pressure decreases the air cut off valve au tomatically closes to guard against a loss of per formance due to self EGR 1 Check Hoses Loose connections Connect properly 3 way joint Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve assembly 3 Check Air cut off valve Cracks damage Replace 4 Check Air cut off valve oper...

Page 254: ...7 13 AIR INDUCTION SYSTEM Air cut off valve opens Replace the air cut off valve Air cut off valve closes Air cut off valve is OK 1 sssssssssssssssssssssssssssss ...

Page 255: ...ON 8 7 TROUBLESHOOTING 8 9 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 13 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 SELF DIAGNOSTIC FUNCTION TABLE 8 32 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 35 TROUBLESHOOTING DETAILS 8 41 8 51 CIRCUI...

Page 256: ...OIL 8 67 CHECKING THE IGNITION SPARK GAP 8 67 CHECKING THE CRANKSHAFT POSITION SENSOR 8 68 CHECKING THE LEAN ANGLE SENSOR 8 68 CHECKING THE STARTER MOTOR OPERATION 8 69 CHECKING THE STATOR COIL 8 69 CHECKING THE RECTIFIER REGULATOR 8 69 CHECKING THE HORN 8 70 CHECKING THE FUELSENDER 8 70 CHECKING THE RADIATOR FAN MOTOR 8 71 CHECKING THE COOLANT TEMPERATURE SENSOR 8 71 CHECKING THE THROTTLE BODY SE...

Page 257: ......

Page 258: ... GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB RL ...

Page 259: ...8 2 IGNITION SYSTEM 3 Battery 4 Crankshaft position sensor 10 Main switch 11 ECU engine control unit 15 Lean angle sensor 18 Ignition coil 41 Spark plug 42 Fuse 43 Engine stop switch ...

Page 260: ...heck the spark plug Refer to CHECKING THE SPARK PLUG on page 3 7 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 67 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 66 Replace the spark plug cap 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 67 Replace the ig...

Page 261: ...e stop switch is faulty Replace the right handlebar switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 68 Replace the lean angle sensor 11 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem wiring Replace the ECU ...

Page 262: ...W Br Br P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 ...

Page 263: ... ELECTRIC STARTING SYSTEM 3 Battery 7 Starter motor 8 Starter relay 9 Starting system cut off relay 10 Main switch 29 Start switch 33 Neutral switch 34 Clutch switch 37 Diode 42 Fuse 43 Engine stop switch ...

Page 264: ...tch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off rela...

Page 265: ...MISSION IS IN NEUTRAL b WHEN CLUTCH LEVER IS PULLED TO THE HANDLEBAR 3 Battery 7 Starter motor 8 Starter relay 9 Starting system cut off relay 10 Main switch 29 Start switch 33 Neutral switch 34 Clutch switch 37 Diode 42 Fuse 43 Engine stop switch ...

Page 266: ...fer to CHECKING THE START ER MOTOR OPERATION on page 8 69 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 35 Repair or replace the starter motor 5 Check the starting circuit cut off re lay Refer to CHECKING THE RE LAYS on page 8 64 Replace the starting circuit cut off relay 6 Chec...

Page 267: ...THE SWITCHES on page 8 57 Replace the neutral switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 57 The start switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or repair the startin...

Page 268: ...P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 4 B B Br B 16 33 12 OrB OrB RL ...

Page 269: ...8 12 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Battery 42 Fuse ...

Page 270: ... CHARGING THE BATTERY on page 8 61 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 69 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 69 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT...

Page 271: ...8 14 CHARGING SYSTEM ...

Page 272: ...P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB ...

Page 273: ...6 LIGHTING SYSTEM 3 Battery 10 Main switch 20 Head light L 21 Tail brake light 28 Pass switch 31 Front brake light switch 32 Rear 38 Head light R 42 Fuse 44 Light switch 46 Dimmer switch brake light switch ...

Page 274: ...SE on page 8 61 Replace the fuse 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 61 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 57 The dimmer switch is faulty Replace the left handlebar switch 6 Check...

Page 275: ...8 18 LIGHTING SYSTEM ...

Page 276: ... P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB...

Page 277: ... Main switch 11 ECU engine control unit 21 Tail light 22 Front Flasher light L 23 Front Flasher light R 24 Rear Flasher light L 25 Rear Flasher light 30 Horn 33 Neutral switch 39 Speed sensor 42 Fuse 45 Fuel sender 48 Turn signal switch ...

Page 278: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 8 61 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Check the condition of each of the sig naling system c...

Page 279: ... brake light switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the rear brake light switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal ligh...

Page 280: ...r to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the neutral indicator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 60 Replace the neutral indicator light bulb socket or both 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the neutral switch 3 Check the entire s...

Page 281: ...8 24 SIGNALING SYSTEM NG OK 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly ...

Page 282: ... GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB R...

Page 283: ...8 26 COOLING SYSTEM 3 Battery 10 Main switch 11 ECU engine control unit 16 Coolant temperature sensor 35 Radiator fan motor 36 Radiator fan motor relay 42 Fuse ...

Page 284: ... the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 71 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 64 Replace the radiator fan motor relay 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERA TU...

Page 285: ...8 28 COOLING SYSTEM ...

Page 286: ...Br Br P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 B B Br B 16 33 12 OrB OrB...

Page 287: ...Fuel injector 13 FID fast idle solenoid device 14 Sensor Module 15 Lean Angle Sensor 16 Coolant temperature sensor 17 Self diagnosis signal connector 18 Ignition coil 19 Fuel pump 29 Engine stop switch 35 Radiator fan motor 36 Radiator fan motor relay 39 Vehicle speed sensor 41 Spark plug 42 Fuse 43 Stop Switch ...

Page 288: ... trouble warning light flashes when the start switch is being pushed to start the engine If a malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light After the engine has been stopped the fault code number appears on t...

Page 289: ...cordance with the description of the mal function Can or cannot be oper ated depending on the fault code 30 Lean angle sensor 41 Lean angle sensor open or short circuit 33 Faulty ignition 50 ECU internal malfunction memory check error 39 Fuel injector open or short circuit a b c c d a Main switch OFF b Main switch ON c Engine trouble warning light off d Engine trouble warning light on for 3 second...

Page 290: ... 30 Lean angle sensor latch up detected No normal signal is received from the lean angle sensor Unable Unable 33 Ignition coil open circuit Primary lead of the ignition coil open circuit detected Unable Unable 39 Fuel injector Fuel injector open or short circuit detected Unable Unable 41 42 Lean angle sensor open or short circuit open or short circuit Speed Sensor Lean angle sensor open or short c...

Page 291: ...the malfunction history in the diagnos tic mode Refer to Sensor operation table Diagnostic code No 62 NOTE Turning the main switch to OFF will not erase the malfunction history Fault code No No fault code No Check and repair Refer to TROUBLE SHOOTING DE TAILS on page 8 40 Monitor the opera tion of the sensors and actuators in the diagnostic mode Re fer to Sensor opera tion table and Actuator opera...

Page 292: ...D of the FI diagnostic tool POWER LED green comes on If a malfunction is detected in the system WARNING LED orange comes on 4 Stop the engine NOTE If a malfunction is detected in the system the fault code appears on the LCD of the FI diagnostic tool And also WARNING LED orange comes on FI diagnostic tool 1 2 FI Diagnostic Tool 0rpm 66 ºC S D 41 Communication error with the FI diagnostic tool LCD D...

Page 293: ...MODE button 6 Select the diagnostic code number corresponding to the fault code number by pressing the UP and DOWN buttons NOTE The diagnostic code number appears on the LCD 01 70 To decrease the selected diagnostic code number press the DOWN button Press the DOWN but ton for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number pr...

Page 294: ...etected Stuck throttle position sensor Malfunction in ECU 01 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Improperly installed coolant temperature sensor 06 22 Intake air temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective air temperature sen...

Page 295: ...stem voltage battery voltage Approximately 12 0 Compare with the actually measured battery voltage If the battery voltage is lower perform recharging 07 Vehicle speed pulse 0 999 Check that the number increase when the front wheel is rotated The number is cumulative and does not reset each time the wheel is stopped 44 Error is detected while reading or writing on EEPROM Malfunction in ECU The CO a...

Page 296: ...on the FI diagnostic tool Check the spark five times Connect an ignition checker 36 Fuel injector When the MODE button is pressed the fuel injector is actuated five times at one second intervals Illuminates the WARNING on the FI diagnostic tool Check the operating sound of the injector five times 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles every five second O...

Page 297: ...2 Malfunction history code erasure No history 00 History exists Up to 14 fault codes T o erase the history press the MODE button of the FI diagnostic tool 70 Control number 0 254 Diag nostic code No Item Actuation Checking method ...

Page 298: ... the crankshaft position sensor coupler and ECU cou pler red red black blue black blue 4 Defective crankshaft position sensor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 68 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the FI diagnostic tool Check and service the items or components that are the probable cause of ...

Page 299: ...n repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler blue red blue red pink white pink white black blue black blue 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace the throttle body if ...

Page 300: ...Check and repair the connec tion Replace throttle body if there is a malfunction Starting the en gine and oper ating it at 1000 rpm and above 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace the throttle body if de fective Refer to CHECKING THE THROTTLE BODY SENSOR ASSEMBL Y on page 8 72 CAUTION Do not remove the throttle body sensor assembly from the throttle ...

Page 301: ... any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler blue red blue red yellow blue yellow blue black blue black blue 4 Defective throttle position sensor ...

Page 302: ...ic code No 06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tempera ture sensor Check the installed area for looseness or pinching Turning the main switch ON 2 Connected state of connector Coolant temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may have ...

Page 303: ... condition of the couplers If there is a malfunction repair it and connect the coupler se curely Turning the main switch ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle body sensor assembly coupler and ECU coupler brown white brown white black blue black blue 3 Defective intake air temperature sen sor Execute the diagnostic mode Co...

Page 304: ...ic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 68 Fault code No 33 Symptom Primary lead of the ignition coil open circuit detected Diagnostic code No 30 Ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Ignition coil connector primary coil side Main wire harness ECU coupler Check the connect...

Page 305: ...ic mode Code No 36 Replace if defective Refer to CHECKING THE FUEL INJECTOR on page 7 6 Fault code No 41 Symptom Lean angle sensor open or short circuit detected Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may b...

Page 306: ...the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BA TTERY on page 8 61 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on p...

Page 307: ...peed sensor coupler Main wire harness ECU coupler Check for looseness or pinching Check the couplers for any pins that may be pulled out Check the locking condition of If there is a malfunction repair it Repair or replace if there is an Execute the diagnostic mode Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 74 Code No 07 Between speed sensor coupler and ECU coupler open or sh...

Page 308: ... P GY GY Br Br B B B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB...

Page 309: ...8 52 FUEL PUMP SYSTEM 3 Battery 10 Main switch 11 ECU engine control unit 19 Fuel pump 42 Fuse 43 Stop switch ...

Page 310: ...he battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 57 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 57 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel pump Refer to CHECKING THE FUEL PUMP BODY on page 7 2 Replace the fuel pump assembly 6 Check th...

Page 311: ...8 54 FUEL PUMP SYSTEM ...

Page 312: ...8 55 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 4 8 17 23 2 3 5 6 7 9 10 11 12 13 14 15 16 18 19 20 21 22 ...

Page 313: ...sition sensor 6 FID fast idle solenoid device 7 Rectifier regulator 8 Lean angle sensor 9 Starting circuit cut off relay 10 Turn signal relay 11 Radiator fan motor relay 12 ECU engine control unit 13 Fuse box 14 Starter relay 15 Battery 16 Rear brake light switch 17 Sidestand switch 18 Neutral switch 19 Crankshaft position sensor 20 Coolant temperature sensor 21 Speed sensor 22 Radiator fan 23 Hor...

Page 314: ...ECTRICAL COMPONENTS CHECKING THE SWITCHES B L W OFF ON R B Br Sb Br Dg Ch Br W P B G Y W B Y Br R B B2 BLACK RED B R G Y B Br Y B G Dg Ch Br W Y P W B Br R W R W L W B PASS 1 2 3 4 5 6 7 8 9 10 11 GY B Br Br B ...

Page 315: ...L COMPONENTS 1 Clutch switch 2 Main switch 3 Front brake light switch 4 Rear brake light switch 5 Neutral switch 6 Turn signal switch 7 Horn switch 8 Dimmer switch 9 Pass switch 10 Engine stop switch 11 Start switch ...

Page 316: ...ecking for continuity set the multimeter to continuity mode l When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed c...

Page 317: ...t bulb get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the ...

Page 318: ...the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to m...

Page 319: ...oltage at the battery terminals 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Battery leads from the battery terminals CAUTION First disconnect the negative battery lead 1 and then positive battery lead 2 3 Remove Battery 4 Check Battery charge a Connect a multimeter to the battery termi nals NOTE The charge state of an MF battery can be checked by measuring its open circuit volt...

Page 320: ...me during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage Charging method using...

Page 321: ...ing voltage is 15 V NOTE Set the charging time at 20 hours maximum e Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals CAUTION First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connec...

Page 322: ...l 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 Br L B 1 2 4 3 1 3 2 4 L B R W L W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 Turn sig...

Page 323: ... shown c Check the diode for continuity d Check the diode for no continuity CHECKING THE SPARK PLUG CAP 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the multimeter Ω 1k to the spark plug cap as shown Turn signal relay output voltage DC 12 V Multimeter Positive tester probe brown white 1 Negative tester probe ground Mu...

Page 324: ...k gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 3 NOTE If the ignition spark gap is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 2 16 2 64 Ω at 20 C 68 F Multimeter Positive tes...

Page 325: ...emove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the multimeter to the sensor coupler as shown c Turn the main switch to ON d Tilt the lean angle sensor to 65 Ignition checker 2 Spark plug cap Crankshaft position sensor resis tance 248 372 Ω at 20 C 68 F Positive tester probe red 1 Ne...

Page 326: ...s 2 Check Stator coil resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the multimeter Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the rectifi er regulator a Set the engine tachometer to the spark plug lead b Connect the multimeter ...

Page 327: ...tained CHECKING THE FUEL SENDER 1 Disconnect Fuel pump assembly coupler from the wire harness 2 Remove Fuel tank 3 Remove Fuel pump assembly from the fuel tank 4 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the multimeter Ω 100 to the fuel sender coupler as shown Positive tester probe red 1 Negative tester probe black 2 Coil resistance 4 30 4 80 Ω at 2...

Page 328: ...e sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the multimeter Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 NOTE Make sure...

Page 329: ...ge is increased Voltage does not change or it changes abruptly Replace the throttle body Out of specification closed position Re place the throttle body Intake air pressure sensor 1 Check Intake air pressure sensor output voltage Out of specification Replace the throttle body a Connect the multimeter to the sensor assembly coupler as shown T R Coolant temperature sensor 18 Nm 1 8 m kg 13 ft lb Pos...

Page 330: ...esistance CHECKING THE FID FAST IDLE SOLENOID 1 Disconnect FID fast idle solenoid device coupler 2 Check FID fast idle solenoid resistance device a Disconnect the FID fast idle solenoid device couplerfrom the wire harness b Connect the multimeter Ω to the terminals of the FID fast idle solenoid device c Measure the FID fast idle solenoid device resistance Out of specification Replace the throttle ...

Page 331: ...n switch to ON c Elevate the front wheel and slowly rotate it d Measure the voltage of gray and gray black With each full rotation of the front wheel the voltage reading should cycle from 0 V to 5 0 V to 0 V to 5 0 V Output voltage reading cycle 0 V to 5 0 V to 0 V to 5 0 V Positive tester probe gray 1 Negative tester probe gray black 2 L G R B L L G B L L R 1 2 Multimeter speed sensor 8 74 ...

Page 332: ...D 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDALDOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 WIRING DIAGRAM 9 5 ...

Page 333: ...lty fuel pump relay 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil Cracked or ...

Page 334: ...ve Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission 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 FAULTY CLUTCH Clutch slips 1 Clutc...

Page 335: ...uid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bol...

Page 336: ...ail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn sign...

Page 337: ... B B L Y G L G G Y L B2 BLUE BLUE B Ch Dg B2 1 5 8 40 9 14 W W W W R BL LB Br RW RW LB LW RB RW BLACK 31 32 BLACK BLACK BLACK 21 23 24 25 22 27 35 39 20 38 36 28 18 RW Or B Or 205 13 11 Br YR YR Br YR Or OrB YR Y GW Br Lg WY B YW BL LR LG R YG BrW YL GR PW BLACK R Br LR PW BL BrW YL TP AC CRK IG VB VCC PB SGND AT BrWPW BL YL LR YL LR PW BL BrW 34 41 42 4 B B Br B 16 33 12 OrB OrB RL RW RL OrB OrBR...

Page 338: ...e minus lead 7 Starter motor 8 Starter relay 9 Ignition cut off relay 10 Main switch 11 ECU 12 Injector 13 FID Fast Idle Solenoid device 14 Sensor module 15 Lean sensor angle 16 Coolant temperature sensor 17 Service tool 18 Ignition coil 19 Fuel Pump 20 Head Light L 21 Tail brake Light 22 FR Flasher Light L 23 FR Flasher Light R 24 RR Flasher Light L 25 RR Flasher Light R 26 Flasher Relay 27 Meter...

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X-MAX 400 ABS 2018

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