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Yamaha YZF-R1P 2001-2003, Service Manual

The Yamaha YZF-R1P 2001-2003 Assembly Manual is a comprehensive guide that provides detailed instructions for assembling and maintaining your bike. This manual is available for free download at manualshive.com, ensuring easy access to the information you need to keep your Yamaha YZF-R1P in top shape.

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3 - 13

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE

VALVE PAD SELECTION TABLE
INTAKE 

EXHAUST

Measured 

clearance

INSTALLED PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 ~ 0.02

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

0.03 ~ 0.07

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

0.08 ~ 0.10

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

0.11 ~ 0.20

Specification

exa 0.21 ~ 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

→

0.23 ~ 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28 ~ 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 ~ 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 ~ 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 ~ 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 ~ 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 ~ 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 ~ 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 ~ 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 ~ 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 ~ 0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 ~ 0.82 185 190 195 200 205 210 215 220 225 230 235 240

EXAMPLE: 

VALVE CLEARANCE: 0.11 ~ 0.20 mm

Installed is 150
Measured clearance is 0.25 mm
Replace 150 pad with 160 pad

0.83 ~ 0.87 190 195 200 205 210 215 220 225 230 235 240
0.88 ~ 0.92 195 200 205 210 215 220 225 230 235 240
0.93 ~ 0.97 200 205 210 215 220 225 230 235 240
0.98 ~ 1.02 205 210 215 220 225 230 235 240
1.03 ~ 1.07 210 215 220 225 230 235 240
1.08 ~ 1.12 215 220 225 230 235 240
1.13 ~ 1.17 220 225 230 235 240
1.18 ~ 1.22 225 230 235 240
1.23 ~ 1.27 230 235 240
1.28 ~ 1.32 235 240
1.33 ~ 1.37 240

Measured 

clearance

INSTALLED PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 ~ 0.02

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215

0.03 ~ 0.07

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

0.08 ~ 0.12

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

0.13 ~ 0.17

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

0.18 ~ 0.20

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

0.21 ~ 0.27

Specification

exa 0.28 ~ 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

→

0.33 ~ 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 ~ 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 ~ 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 ~ 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 ~ 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 ~ 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 ~ 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 ~ 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 ~ 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 ~ 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 ~ 0.87 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88 ~ 0.92 185 190 195 200 205 210 215 220 225 230 235 240

EXAMPLE: 

VALVE CLEARANCE: 0.21 ~ 0.27 mm

Installed is 175
Measured clearance is 0.35 mm
Replace 175 pad with 185 pad 

0.93 ~ 0.97 190 195 200 205 210 215 220 225 230 235 240
0.98 ~ 1.02 195 200 205 210 215 220 225 230 235 240
1.03 ~ 1.07 200 205 210 215 220 225 230 235 240
1.08 ~ 1.12 205 210 215 220 225 230 235 240
1.13 ~ 1.17 210 215 220 225 230 235 240
1.18 ~ 1.22 215 220 225 230 235 240
1.23 ~ 1.27 220 225 230 235 240
1.28 ~ 1.32 225 230 235 240
1.33 ~ 1.37 230 235 240
1.38 ~ 1.42 235 240
1.43 ~ 1.47 240

Summary of Contents for YZF-R1P 2001-2003

Page 1: ......

Page 2: ......

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

Page 4: ......

Page 5: ...by Yamaha Motor Corporation U S A First edition December 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly pr...

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

Page 7: ...age except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify p...

Page 8: ...fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication p...

Page 9: ......

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

Page 11: ...INSTRUMENT FUNCTION 1 20 IMPORTANT INFORMATION 1 23 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 23 REPLACEMENT PARTS 1 23 GASKETS OIL SEALS AND O RINGS 1 23 LOCK WASHERS PLATES AND COTTER PINS 1 24 BEAR...

Page 12: ...MS 2 25 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 30 CABLE ROUTING 2 35 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SY...

Page 13: ...E 3 37 ADJUSTING THE REAR BRAKE 3 38 CHECKING THE BRAKE FLUID LEVEL 3 39 CHECKING THE FRONT AND REAR BRAKE PADS 3 40 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 40 CHECKING THE FRONT AND REAR BRAKE HOSES...

Page 14: ...PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE MASTER CYLINDER 4 26 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT AND R...

Page 15: ...K ABSORBER ASSEMBLY 4 68 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 68 SWINGARM AND DRIVE CHAIN 4 69 REMOVING THE SWINGARM 4 71 REMOVING THE DRIVE CHAIN 4 72 CHECKING THE SWINGARM 4 72 CHECKING THE...

Page 16: ...5 33 PICKUP COIL 5 36 REMOVING THE PICKUP COIL ROTOR 5 38 INSTALLING THE PICKUP COIL ROTOR 5 38 CLUTCH 5 40 CLUTCH COVER 5 40 PULL LEVER SHAFT 5 41 CLUTCH 5 42 REMOVING THE CLUTCH 5 44 CHECKING THE F...

Page 17: ...T AND CHAINS 5 61 ASSEMBLING THE CRANKCASE 5 62 CONNECTING RODS AND PISTONS 5 64 REMOVING THE CONNECTING RODS AND PISTONS 5 65 REMOVING THE CRANKSHAFT ASSEMBLY 5 66 CHECKING THE CYLINDER AND PISTONS 5...

Page 18: ...PUMP 6 14 ASSEMBLING THE WATER PUMP 6 15 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7 1 WIRING DIAGRAM 7 2 ECU S SELF DIAGNOSTIC FUNCTION 7 3 SUBSTITUTE CHARACTERISTICS OPERATION CONTROL F...

Page 19: ...OF THE BULB SOCKETS 8 7 CHECKING THE LEDs 8 7 IGNITION SYSTEM 8 8 CIRCUIT DIAGRAM 8 8 TROUBLESHOOTING 8 9 ELECTRIC STARTING SYSTEM 8 13 CIRCUIT DIAGRAM 8 13 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8...

Page 20: ...2 INCORRECT ENGINE IDLING SPEED 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 ELECTRICAL SYSTEMS 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICU...

Page 21: ...SIGNALING SYSTEM 9 6 HEADLIGHT DOES NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT COME ON 9 6 TURN SIGNAL...

Page 22: ...0017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This info...

Page 23: ...fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor sys...

Page 24: ...injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressu...

Page 25: ...Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection...

Page 26: ...are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection timing and ignition timi...

Page 27: ...tion system relay when the lean angle cut off switch is oper ated 2 Operating the headlight illumination relay The ECU controls the headlight relay 2 in accordance with the engine speed as required by...

Page 28: ...e pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to prevent the fuel p...

Page 29: ...g force An intake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the diaph...

Page 30: ...the flange that is integrated with the plunger to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant...

Page 31: ...the ECU which calculates the position of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calcu lated data in order to determine the correspond...

Page 32: ...aust side head cover When the exhaust camshaft rotates the sensor generates a signal and sends it to the ECU Based on this sig nal and the signal from the crankshaft position sensor the ECU then actua...

Page 33: ...the moving contact that moves in unison with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output...

Page 34: ...silicon diaphragm con verts the intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate el...

Page 35: ...s which are then input into the ECU 1 Connector 2 Terminal 3 Tube 4 Thermistor 5 Holder Resistance k Temperature C F Intake temperature sensor The intake temperature sensor corrects the deviation of t...

Page 36: ...e exceeds 65 degrees according to the tilt of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the moto...

Page 37: ...on command to the injectors Further more the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on the signals from th...

Page 38: ...n and determines the final injection duration based on the operating condition of the engine Composition of final injection duration 1 Injection at start 1 2 After start enrichment 2 3 Warm up enrichm...

Page 39: ...engine speed by stopping the injection of fuel into two cylinders when the engine speed becomes greater than the specified value If the engine speed increases further this control stops the injection...

Page 40: ...o an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion Through the joint effort of these control systems the exhaus...

Page 41: ...ushing the SELECT button switches the display between the various tripmeter and odome ter modes in the following order F TRIP TRIP A TRIP B ODO F TRIP To reset a tripmeter select it by pushing the SEL...

Page 42: ...e the SELECT button was last pushed will be applied In this mode the multi function display shows the current setting for each function except the engine speed indicator light activity function To adj...

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

Page 44: ...parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLA...

Page 45: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the b...

Page 46: ...disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all c...

Page 47: ...ove the genera tor rotor YU 01235 Rotor holding tool This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt YU 01304 Piston pin pu...

Page 48: ...the front fork legs YM 01442 Fork seal driver This tool is used to install the front fork s oil seal and dust seal YU 08030 Carburetor synchronizer This guide is used to synchronize the carburetors Co...

Page 49: ...ver This tool is used to remove or install the valve guides 4 mm 0 16 in 90890 04112 4 5 mm 0 18 in YM 4117 Valve guide installer This tool is used to install the valve guides 4 mm 0 16 in 90890 04113...

Page 50: ...compressor This tool is used to compress the piston rings when installing the piston into the cylinder YM 03176 Fuel pressure adapter This tool is needed to measure fuel pressure YU 03153 Pressure gau...

Page 51: ...5 mm 27 8 in Overall height 1 105 mm 43 5 in Seat height 820 mm 32 3 in Wheelbase 1 395 mm 54 9 in Minimum ground clearance 140 mm 5 5 in Minimum turning radius 3 900 mm 153 5 in Weight Wet with oil a...

Page 52: ...nleaded gasoline only Fuel tank capacity Total including reserve 17 L 3 74 Imp gal 4 49 US gal Reserve only 3 3 L 0 73 Imp gal 0 87 US gal Engine oil Lubrication system Wet sump Recommended oil Yamalu...

Page 53: ...pressure 95 125 kPa 0 95 1 25 kg cm2 13 8 18 1 psi Radiator core Width 340 mm 13 4 in Height 295 8 mm 11 6 in Depth 27 mm 1 06 in Coolant reservoir Capacity 0 24 L 0 21 Imp qt 0 25 US qt Water pump W...

Page 54: ...learance 0 028 0 062 mm 0 0011 0 0024 in Intake camshaft lobe dimensions Measurement A 32 5 32 6 mm 1 2795 1 2835 in 32 4 mm 1 2756 in Measurement B 24 95 25 05 mm 0 9823 0 9862 in 24 85 mm 0 9783 in...

Page 55: ...9 1 1 mm 0 0354 0 0433 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Valve margin thickness D Intake 0 5 0 9 mm 0 0197 0 0354 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 3 975 3 990 mm...

Page 56: ...37 0 mm 1 46 in Exhaust 40 67 mm 1 60 in 38 6 mm 1 52 in Installed length valve closed Intake 34 5 mm 1 36 in Exhaust 35 mm 1 38 in Compressed spring force installed Intake 82 96 N 8 2 9 6 kg 18 43 2...

Page 57: ...in Height H 5 mm 0 2 in Piston pin bore in the piston Diameter 17 002 17 013 mm 0 6694 0 6698 in 17 043 mm 0 6710 in Offset 0 5 mm 0 02 in Offset direction Intake side Piston pins Outside diameter 16...

Page 58: ...0138 in Connecting rods Crankshaft pin to big end bearing clearance 0 031 0 055 mm 0 0012 0 0022 in Bearing color code 1 Violet 0 White 1 Blue 2 Black Crankshaft Width A 52 40 57 25 mm 2 06 2 25 in W...

Page 59: ...mm 0 004 in Clutch springs Free length 6 5 mm 0 26 in Spring quantity 1 Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 68 43 1 581 Sec...

Page 60: ...85 5 15 k at 20 C 68 F Output voltage at idle Adjusted by tachometer Throttle bodies Model manufacturer quantity 40EIS MIKUNI 4 Intake vacuum pressure 25 3 kPa 190 mmHg 7 48 inHg Throttle cable free p...

Page 61: ...Max radial wheel runout 1 mm 0 04 in Max lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 ZR17 58W Model manufacturer Pilot SPORT E MICHELIN D208FL DUNLOP Tire pressure co...

Page 62: ...diameter 30 1 mm and 27 mm 1 19 in and 1 06 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position from the top of the brake pedal to the bottom of the rider f...

Page 63: ...nding limit 0 2 mm 0 008 in Optional spring available No Fork oil Recommended oil Suspension oil 01 or equivalent Quantity each front fork leg 0 543 L 0 478 Imp qt 0 574 US qt Level from the top of th...

Page 64: ...lable No Standard spring preload gas air pressure 1 200 kPa 12 kg cm2 174 psi Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9 Rebound damping adjusting positions Minimum 20 Standard...

Page 65: ...r coil resistance color 0 19 0 23 at 20 C 68 F W W Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH001 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier c...

Page 66: ...Horn Horn type Plain Model manufacturer quantity YF 12 NIKKO 1 Max amperage 3 A Performance 105 113 db 2 m 6 6 ft Coil resistance 1 15 1 25 at 20 C 68 F EXUP servo motor Type manufacturer 5PW YAMAHA...

Page 67: ...otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 0393...

Page 68: ...aft sprocket Bolt M7 4 24 2 4 17 Water pump inlet pipe Bolt M6 1 10 1 0 7 2 LT Water pump outlet pipe Bolt M6 1 10 1 0 7 2 LT Oil water pump assembly driven sprocket Bolt M6 1 15 1 5 11 LT Oil pump Bo...

Page 69: ...Pick up rotor cover Bolt M6 8 12 1 2 8 7 Shift shaft cover Bolt M6 5 12 1 2 8 7 Breather plate Bolt M6 5 10 1 0 7 2 LT Timing mark accessing screw Bolt M8 1 15 1 5 11 Starter clutch idle gear shaft B...

Page 70: ...32 Nm 3 2 m kg 23 ft lb with a torque wrench EXUP servo motor cover Screw M5 2 2 0 2 1 4 Intake air temperature sensor M12 1 18 1 8 13 Cylinder identification sensor Bolt M6 1 10 1 0 7 2 LT Atmospher...

Page 71: ...d inner panel M5 1 0 1 0 7 Grip end and handlebar M6 4 0 4 2 9 Brake hose holder and under bracket M6 7 0 7 5 1 Engine mounting Front mounting bolts M10 45 4 5 33 Rear mounting bolts upper and lower M...

Page 72: ...ressure sensor and battery box M5 0 7 0 07 0 5 Lean angle cut off switch sensor and battery box M4 2 0 2 1 4 Rider footrest bracket and frame M8 28 2 8 20 Passenger footrest bracket and frame M8 28 2...

Page 73: ...nd outer E Oil pump housing E Oil strainer E Clutch pull rod LS Oil water pump drive sprocket and washer E Clutch thrust plate E Starter clutch idle gear inner surface E Starter clutch assembly E Prim...

Page 74: ...el drive hub mating surface LS Rear brake pedal shaft LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivoting point and metal to metal moving...

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

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

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

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

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

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

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

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

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

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

Page 85: ...ng the head light leads and position lamp leads at the place of white tape with the clamp behind the pawl of headlight body To turn signal light To main harness Route the junction of the head light po...

Page 86: ...n 7 AC magneto lead 8 Speed sensor lead 9 lead 0 Rear brake switch lead A EXUP servo motor lead B AC magneto lead C AI system lead D Oil level switch lead E Sidestand switch lead F Wire harness assemb...

Page 87: ...ition sensor lead under the throttle body Wiring section Connect the leads behind the clamp without crankshaft position sensor lead Fasten the wire harness speed sensor neutral switch rear brake switc...

Page 88: ...the clamp inserted to the box battery Clamp the lead as being in parallel along the fender Make sure to clamp three leads Fasten the wire harness with the clamp inserted to the hole of the box batter...

Page 89: ...ad Press the lead of the coupler for ALARM in under the cou pler of ECU Pay attention not to allow the lead to slack and get caught after wiring when assembling the side cover Make sure to hook the ha...

Page 90: ...n side to the vehi cle outside Fasten the clutch cable with the clamp to the inside of the coolant reservoir tank Fasten the sidestand switch lead behind the bracket and cut the tip To fuel tank Pass...

Page 91: ...behind of the throttle cable Route the coolant temperature sensor lead between the engine and the radiator hose Route the clutch cable through the inside of radiator hose and fasten it with the clamp...

Page 92: ...hose G Oil level gauge lead H AI system hose I Sidestand switch lead J Fuel return hose K Fuel tank breather hose L Fuel feeder hose M Fuel tank drain hose N Injector sub lead O Wire harness P To thr...

Page 93: ...or hose in the drive sprocket cover Do not pinch the hose Pass the oil level gauge lead and sidestand switch lead by the inner side of the coolant hose Route the fuel tank breather hose and fuel tank...

Page 94: ...rting direction of the relay Fasten the EXUP servo motor lead with the clamp inserted to the frame Fasten the wire harness with the clamp inserted to the hole of battery box Point the tip of clamp upw...

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

Page 96: ...3 30 Check for leakage Retighten if necessary Replace gasket s if necessary 6 Electronic fuel injection See page 3 14 Check and adjust engine idle speed and syn chronization 7 Evaporative emis sion co...

Page 97: ...mi 25 000 km or 24 months Replace 9 Rear suspension link pivots See page 4 71 Check operation Correct if necessary 10 Shock absorber assembly See page 4 68 Check operation and for oil leakage Replace...

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

Page 99: ...Removing the fuel tank Remove the parts in the order listed Rider seat Refer to SEATS 1 Bolt 1 2 Bolt 1 3 Fuel sender coupler 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose connector cover...

Page 100: ...there may be fuel remain ing in it NOTE Before removing the hoses place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal...

Page 101: ...pump as shown in the illustra tion Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose f...

Page 102: ...he order listed Rider and passenger seats Refer to SEATS 1 Tail cowling 1 2 Bottom cowling 1 3 Front cowling inner panel left 1 4 Front cowling inner panel right 1 5 Left side cowling 1 6 Right side c...

Page 103: ...seat and fuel tank Refer to SEATS and FUEL TANK 1 Crankcase breather hose 1 2 Air filter case breather hose 1 3 Al system hose 1 4 Intake temperature sensor coupler 1 5 Clamp screw 4 Loosen 6 Bolt 1 7...

Page 104: ...or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case ignition coil plate Refer to AIR FILTER CASE...

Page 105: ...ith a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence Front d To measure the valve clearances of the other...

Page 106: ...o prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve...

Page 107: ...w valve pad number NOTE The new valve pad number is only an approxi mation The valve clearance must be mea sured again and the above steps should be repeated if the measurement is still incorrect e In...

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

Page 109: ...valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 7 Install all removed parts NOTE For installation reverse t...

Page 110: ...a With throttle body 3 as standard adjust throttle bodies 1 2 and 4 using the air screw 1 NOTE After each step rev the engine two or three times each time for less than a second and check the synchron...

Page 111: ...11 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY 12 Remove digital tachometer carburetor syncronizer 13 Remove fuel tank 14 Install fuel tank Refer to FUEL TANK ride...

Page 112: ...e free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE _ Prior to adjusting the throttle cable free play the engine idling speed should be adj...

Page 113: ...tor cable c Loosen the locknut 4 on the accelerator cable d Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained e Tighten the locknuts NOTE _ If the s...

Page 114: ...CKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove rider seat Refer to SEATS fuel tank Refer to FUEL TANK air filter case ignition coil plates rubber baffle Refer...

Page 115: ...ut of specification Regap 7 Install spark plug ignition coil NOTE _ Before installing the spark plug clean the spark plug and gasket surface 8 Install rubber baffle ignition coil plates air filter cas...

Page 116: ...tank Refer to FUEL TANK air filter case ignition coil plates rubber baffle Refer to AIR FILTER CASE 4 Remove spark plug ignition coil CAUTION _ Before removing the spark plugs use com pressed air to...

Page 117: ...e cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the...

Page 118: ...on a suitable stand Make sure the motorcycle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check engine oil level The engine oil level should be between the mini...

Page 119: ...ace a container under the engine oil drain bolt 3 Remove bottom cowling Refer to COWLINGS engine oil filler cap engine oil drain bolt 1 along with the gasket 4 Drain engine oil completely from the cra...

Page 120: ...cified amount of the recom mended engine oil 9 Install engine oil filler cap bottom cowling Refer to COWLINGS 10 Start the engine warm it up for several min utes and then turn it off 11 Check engine f...

Page 121: ...not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PAN AND OIL PUMP in chapter 5 d Start the engine after solving the problem s and...

Page 122: ...nt procedure described below 3 Remove bottom cowling Refer to COWLINGS Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased 4 Adjust clutch mechanism Engine...

Page 123: ...allu wet or dusty areas 4 Install air filter case cover CAUTION _ Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage...

Page 124: ...l hose 2 Cracks damage Replace Loose connection Connect properly NOTE Before removing the fuel hoses place a few rags in the area under where it will be removed 3 Install fuel tank Refer to FUEL TANK...

Page 125: ...as leaks Replace 3 Check tightening torque NOTE Install the spring 0 with its longer part a positioned upward Upper part 2 of the EXUP cable is attached with the rubber boot cover Install the EXUP cab...

Page 126: ...ximum EXUP cable free play at the EXUP valve pulley 1 5 mm 0 059 in 5 Adjust EXUP cable free play a Loosen both locknuts 1 b Insert a 4 mm long pin through the notch in the EXUP valve pulley and into...

Page 127: ...inimum level mark b Below the minimum level mark Add the recommended coolant to the proper level CAUTION _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used...

Page 128: ...LINGS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler 4 oil cooler inlet hose 5 oil cooler outlet hose 6 water jacket joint inlet hose 7 water pump inlet pipe 8 water pump o...

Page 129: ...ne has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to...

Page 130: ...n CAUTION _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant...

Page 131: ...mum level mark a 13 Install coolant reservoir cap 14 Start the engine warm it up for several min utes and then stop it 15 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking...

Page 132: ...e arrow mark 2 on the brake lever holder WARNING _ A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be remov...

Page 133: ...knut 1 to specification WARNING _ A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding th...

Page 134: ...may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful...

Page 135: ...rake Rear brake EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE _ The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the b...

Page 136: ...DRAULIC BRAKE SYSTEM WARNING _ Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation...

Page 137: ...n position g Loosen the bleed screw NOTE _ Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the b...

Page 138: ...e tightest point on the chain CAUTION _ A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident T...

Page 139: ...To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to specification e Tighten the wheel axle nut to specification CAUTION _ Do not loosen the wheel axle nut after...

Page 140: ...y kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suit able for O ring chains Do not use any other lubricants on the d...

Page 141: ...ight angle to the steering nut wrench c Loosen the lower ring nut completely then tighten it to specification WARNING _ Do not overtighten the lower ring nut d Check the steering head for looseness or...

Page 142: ...ll of the cables and wires are prop erly routed T R 115 Nm 11 5 m kg 83 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 26 Nm 2 6 m kg 19 ft lb a Point the front wheel straight ahe...

Page 143: ...t fork Binding looseness Adjust the steering head EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it...

Page 144: ...Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION _ Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum...

Page 145: ...Never go beyond the maximum or mini mum adjustment positions Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting posit...

Page 146: ...on b with the adjusting screw fully turned in direction a EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING _ Securely support the motorcycle so that there is no danger of it falling over Sp...

Page 147: ...imum 1 Standard 4 Maximum 9 1 Adjust rebound damping a Turn the adjusting screw 1 in direction a or b Compression damping CAUTION _ Never go beyond the maximum or mini mum adjustment positions Directi...

Page 148: ...temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overlo...

Page 149: ...3 kg 426 lb For California 194 kg 428 lb Maximum load For USA Canada 202 kg 445 lb For California 201 kg 443 lb Cold tire pressure Front Rear Up to 90 kg 198 lb load 250 kPa 2 5 kgf cm2 36 3 psi 250 k...

Page 150: ...hing a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tire Wheel WARNING After extens...

Page 151: ...ark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Manufacturer Size Model DUNLOP 120 70ZR 17M C 58W D208FL MICHELIN 120 70ZR 17M C 58W Pilot SPORT E Ma...

Page 152: ...NOTE _ Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point a...

Page 153: ...it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Dr...

Page 154: ...attery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No charging is necessary when the open cir cuit voltage equals or excee...

Page 155: ...charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the b...

Page 156: ...or the amperage for 3 5 minutes to check if the standard charging current is reached NO YES If the current does not exceed the standard charging current after 5 minutes replace the bat tery If chargin...

Page 157: ...arge the battery until the battery s charging voltage is 15 V Measure the battery open circuit volt age after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12...

Page 158: ...s 10 Install rider seat Refer to SEATS EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checkin...

Page 159: ...than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could pos...

Page 160: ...and your hands away from the bulb until it has cooled down 4 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder CAUTION _ Avoid touching the glass part of the head lig...

Page 161: ...ically a Turn the adjusting screw 1 in direction a or b 2 Adjust headlight beam horizontally a Turn the adjusting screw 2 in direction a or b Direction a Headlight beam is raised Direction b Headlight...

Page 162: ...on a suitable stand so that the front wheel is elevated 1 Brake hose holder left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 4 Loosen 4 Wheel axle bolt 1 5 Front wheel axle 1...

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

Page 164: ...emove left brake caliper right brake caliper NOTE Do not apply the brake lever when removing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front wh...

Page 165: ...ls a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE _ To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c...

Page 166: ...the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc 3 Measu...

Page 167: ...with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Install the brake calipers by installing the bolts and then tightening them to the spe...

Page 168: ...front brake push down hard on the handlebar several times to check for proper fork operation T R Wheel axle pinch bolt 18 Nm 1 8 m kg 13 ft lb T R Wheel axle pinch bolt 18 Nm 1 8 m kg 13 ft lb EAS0054...

Page 169: ...the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE _ Start with the lightes...

Page 170: ...motorcycle on a suitable stand so that the rear wheel is elevated 1 Brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Wheel axle nut 2 5 Washer 1 6 Rear whe...

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

Page 172: ...Job Part Q ty Remarks Remove the brake disc and rear wheel sprocket Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel sprocket 1 3 Collar left and right 2 4 Oil seal 1 5 Bearing 1 6 Rea...

Page 173: ...ger of it falling over NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove brake caliper 1 NOTE _ Do not depress the brake pedal when remov ing the brake calipe...

Page 174: ...earings oil seals Refer to CHECKING THE FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure radial wheel runout lateral w...

Page 175: ...wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear...

Page 176: ...axle nut is not aligned with the cotter pin hole in the wheel axle tighten the nut further until they are aligned Drive chain slack 40 50 mm 1 57 1 97 in T R 150 Nm 15 m kg 108 ft lb T R 27 Nm 2 7 m k...

Page 177: ...40 Nm 4 0 m kg 29 ft Ib Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad c...

Page 178: ...3 ft Ib T R 27 Nm 2 7 m kg 20 ft Ib Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake caliper 1 2 Brake pad 2 3 Brake pad shim 2 2 4 Brake pad spri...

Page 179: ...Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid...

Page 180: ...s 1 along with the brake pad shims 4 Measure brake pad wear limit Out of specification Replace the brake pads as a set 5 Install brake pad shims onto the brake pads brake pads brake pad spring NOTE _...

Page 181: ...e pads and a new brake pad spring NOTE _ The arrow mark a on the brake pad spring must point in the direction of disc rotation 6 Install brake pad pins brake pad clips brake caliper T R Bleed screw 6...

Page 182: ...e or disas semble the brake caliper 1 Remove brake caliper 1 2 Remove brake pads 1 along with the brake pad shims 3 Measure brake pad wear limit Out of specification Replace the brake pads as a set 4...

Page 183: ...bleed screw d Install a new brake pad shim 3 onto each new brake pad 4 5 Install brake caliper T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R 27 Nm 2 7 m kg 20 ft lb 6 Check brake fluid level Below the...

Page 184: ...inder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diap...

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

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

Page 187: ...the rear brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Bra...

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

Page 189: ...oupler 1 from the brake switch 2 Remove union bolt 2 copper washers 3 brake hoses 4 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hos...

Page 190: ...nder Damage scratches wear Replace brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air Front Rear 2 Check brake master cylinder kit Damage scratches wear...

Page 191: ...facing up Align the end of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt then the lower bolt 2 Install copper washers brake hose union bol...

Page 192: ...r 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...

Page 193: ..._ Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already i...

Page 194: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 6 Adjust rear brake light operation...

Page 195: ...30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks Removing the front brake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers Brake flu...

Page 196: ...front brake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5...

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

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

Page 199: ...e hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow...

Page 200: ...e hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the...

Page 201: ...d 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly brake caliper body 3 Cracks damage...

Page 202: ...r is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routi...

Page 203: ...r 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...

Page 204: ...commended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to...

Page 205: ...r 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...

Page 206: ...t Q ty Remarks Removing the front fork legs Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front cowling inner panels Refer to COWLINGS in chapter 3 1 Front fend...

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

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

Page 209: ...is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 handlebar boss pinch bolt 3 lower bracket pinch bolt WARNING _ Before loosening the upper and lower bracket pinch bolts support the front for...

Page 210: ...pring is compressed f Remove the spacer and nut Fork spring compressor YM 01441 Rod holder YM 01434 2 Remove dust seal oil seal clip 1 oil seal washer with a flat head screwdriver CAUTION Do not scrat...

Page 211: ...length a Out of specification Replace Spring free length 246 mm 9 69 in 3 Check damper rod 1 Damage wear Replace obstruction Blow out all of the oil pas sages with compressed air CAUTION The front for...

Page 212: ...mbling the front fork leg make sure all of the components are clean 1 Install damper rod assembly 1 CAUTION _ Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes fr...

Page 213: ...cate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install oil s...

Page 214: ...l 10 Install nut 1 fork spring 2 spring seat 3 spacer 4 damper adjusting rod 5 cap bolt 6 a Remove the rod puller and adapter b Install the nut c Install the fork spring spring seat and spacer NOTE _...

Page 215: ...1 and position it as specified b h Set the cap bolt distance c to specification i Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt j Hold the cap bolt and tighten th...

Page 216: ...ork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt cap bolt 1 handlebar boss pinch bolt 2 upper bracket pinch bolt 3 WARNING _ Make sure the brake hoses are rout...

Page 217: ...1 3 m kg 9 4 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks Removing the handlebars Remove the parts in the order listed 1 Left grip end 1 2 Handlebar grip 1 3 Clutch switch connector 2...

Page 218: ...2 9 ft Ib Order Job Part Q ty Remarks 11 Front brake switch connector 2 Disconnect 12 Right handlebar switch 1 13 Brake master cylinder bracket 1 14 Brake master cylinder 1 15 Handlebar pinch bolt 4 1...

Page 219: ...rip off the handlebar 3 Remove throttle cable housing 1 throttle grip 2 NOTE _ While removing the throttle cable housing pull back the rubber cover 3 EAS00669 CHECKING THE HANDLEBARS 1 Check left hand...

Page 220: ...er bolt NOTE _ Align the mating surfaces of the brake mas ter cylinder holder with the punch mark a in the right handlebar There should be 2 mm of clearance between the right handlebar switch and the...

Page 221: ...e left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 8 Adjust clutch cable free play Refer to ADJUS...

Page 222: ...marks Removing the lower bracket Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK 1 Main switch coupler 2 Disconnect 2 Upper br...

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

Page 224: ...steering nut wrench 2 WARNING _ Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Steering nut wrench YU 33...

Page 225: ...ck upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races 2 Install lower ring...

Page 226: ...rber assembly Remove the parts in the order listed 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt spacer 1 1 1 4 Rear shock absorber assembly 1 5 Collar oil seal beari...

Page 227: ...or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or...

Page 228: ...motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear shock absorber assembly lower bolt 1 relay arm to swingarm bolt 2 NOTE While removing the rear shock absorber assembly l...

Page 229: ...eals Damage wear Replace bolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate spacers bearings 2 Install rear shock absorber assembly NOTE _ When installing...

Page 230: ...ft Ib Order Job Part Q ty Remarks Removing the swingarm and drive chain Remove the parts in the order listed Rear wheel Refer to REAR WHEEL AND BRAKE DISC Rear shock absorber Refer to REAR SHOCK ABSO...

Page 231: ...3 6 ft Ib T R 105 Nm 10 5 m kg 76 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks 8 Drive chain 1 9 Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Bearin...

Page 232: ...olt hold the swingarm so that it does not drop down 3 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play by m...

Page 233: ..._ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove drive chain with the drive chain cutter NOTE Only cut the drive chain if it or the swingarm is to be replaced EAS...

Page 234: ...3 oil seals 4 Damage pitting Replace 7 Check collars 5 Damage scratches Replace EAS00709 CHECKING THE DRIVE CHAIN 1 Measure ten link section a of the drive chain Out of specification Replace the driv...

Page 235: ...High pressure meth ods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to...

Page 236: ...se the pivot shaft wrench 2 to tighten the pivot adjust bolt to specification torque 2 Install relay arm connecting arms NOTE _ Install the connecting arm front bolt 1 from the left 3 Install rear sho...

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

Page 238: ...pipe Remove the parts in the order listed Rider seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHAN...

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

Page 240: ...lter case Refer to AIR FILTER CASE in chapter 3 Throttle body assembly Refer to THROTTLE BODIES in chapter 7 Engine oil and oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Oil...

Page 241: ...4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect 6 Ground lead 1 Disconnect 7 Starter motor 1 8 Stator coil assembly coupler 1 Disconnect 9 Pickup coil coupler 1 Disconnect 10 Oil level s...

Page 242: ...R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine 1 Pinch bolt 2 Loosen 2 Right fr...

Page 243: ...gine mounting adjust bolt 2 Tighten the bolts in the following order Pivot shaft wrench YM 01471 T R Engine mounting adjust bolt 1 7 Nm 0 7 m kg 5 1 ft lb Self locking nut 3 50 Nm 5 0 m kg 36 ft lb Le...

Page 244: ...nder head covers Remove the parts in the order listed Throttle body assembly Refer to THROTTLE BODIES in chap ter 7 Radiator assembly and thermostat assembly Refer to RADIATOR and THERMO STAT in chapt...

Page 245: ...e order listed Pickup coil rotor cover Refer to PICKUP COIL 1 Timing chain tensioner cap bolt 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Timing chain guide exhaust side 1 5 Intak...

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

Page 247: ...ke align the TDC mark a on the pickup coil rotor with the crankcase mating surface b NOTE _ TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Loosen...

Page 248: ...ttern working from the outside in 7 Remove intake camshaft 1 exhaust camshaft 2 EAS00204 CHECKING THE CAMSHAFTS 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft 2 Measu...

Page 249: ...aft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps NOTE _ Tighten the...

Page 250: ...ES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check timing chain 1 Damage stiffness Replace the timing chain and camshaft sprockets as a set 2 Check cam...

Page 251: ...camshaft 1 intake camshaft 2 with the camshaft sprockets temporarily tightened NOTE _ Make sure the punch mark a faces up 2 Install dowel pins intake camshaft caps exhaust camshaft caps NOTE _ Make s...

Page 252: ...sprockets and then install the camshaft sprockets onto the camshafts NOTE _ When installing the camshaft sprockets start with the exhaust camshaft and be sure to keep the timing chain as tight as poss...

Page 253: ...ld face UP WARNING _ Always use a new gasket c Tighten the timing chain tensioner bolts 3 to the specified torque d Remove the screwdriver mark sure that the timing chain tensioner rod releases and th...

Page 254: ...ts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Install timing chain guide top side 11 Measure valve clearance Out of specification Adjust Refe...

Page 255: ...14 ft lb 2nd 121 or 50 Nm 5 0 m kg 36 ft lb T R 1st 20 Nm 2 0 m kg 14 ft lb T R 12 Nm 1 2 m kg 8 7 ft Ib Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Eng...

Page 256: ...void damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Plac...

Page 257: ...tely 20 Nm 2 0 m kg 14 ft lb with a torque wrench Retighten the nuts to specification torque NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tighteni...

Page 258: ...ve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intak...

Page 259: ...lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust v...

Page 260: ...einstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into...

Page 261: ...al and installation and to maintain the correct fit heat the cylinder head to 100 C in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guid...

Page 262: ...16 Valve guide installer Intake 4 0 mm 0 16 in 90890 04112 Exhaust 4 5 mm 0 18 in YM 4117 Valve guide reamer Intake 4 0 mm 0 16 in 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 5 Measure valve margin thi...

Page 263: ...e Dykem 1 onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NO...

Page 264: ...d repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem onto the valve face h...

Page 265: ...at 35 mm 1 38 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake valve spring 1 7 mm 0 067 in Exhaust valve spring 1 8 mm 0 071 in EAS00242 CHECKI...

Page 266: ...larger pitch a facing up b Smaller pitch NOTE Make sure that each valve is installed in its original place Refer to the following embossed marks Right and left intake valve s 4XV Middle intake valve...

Page 267: ...CAUTION _ Hitting the valve tip with excessive force could damage the valve 6 Install valve pad 1 valve lifter 2 NOTE _ Lubricate the valve lifter and valve pad with molybdenum disulfide oil The valv...

Page 268: ...Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Generator rotor cover 1 2 Generator rotor cover...

Page 269: ...NOTE While holding the generator rotor 2 with the rotor holding tool 3 loosen the generator rotor bolt 3 Remove generator rotor 1 with the flywheel puller 2 and rotor holding tool 3 Rotor holding too...

Page 270: ...the generator rotor bolt WARNING Replace the rotor bolt and washer with new ones Clean the rotor bolt NOTE The tightening procedure of rotor bolt is angle controlled therefore tighten the nuts using t...

Page 271: ...and per form the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagon bolt note t...

Page 272: ...Remove the parts in the order listed Rider seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling and right side cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to C...

Page 273: ...Nm 1 5 m kg 11 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 7 Crankshaft position sensor coupler 1 Disconnect 8 Crankshaft position sensor 1 9 Pickup coi...

Page 274: ...e fully loosened remove them 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the rotor holding tool 4 loosen the pickup coil rotor bolt Rotor...

Page 275: ...3 ft lb 3 Apply sealant onto the crankshaft position sensor lead grommet Quick Gasket ACC 11001 05 01 4 Install pickup coil rotor cover pickup coil lead holder clutch cable holder NOTE When installing...

Page 276: ...rks Removing the clutch cover Remove the parts in the order listed Bottom cowling and right side cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1...

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

Page 278: ...the parts in the order listed 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 7 Inside diameter 124 mm 7 Clutch p...

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

Page 280: ...ch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering Universal clutch holder YM 91042 EAS00280 CHECKING THE FRICTION...

Page 281: ...plate warpage limit 0 1 mm 0 004 in EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE _ Pitting on...

Page 282: ...AND PULL ROD 1 Check pull lever shaft pinion gear teeth 1 pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 2 Check pull rod bearing Damage wear Replace EAS0...

Page 283: ...rive gear counterclockwise it should turn freely otherwise the starter clutch is faulty and must be replaced EAS00299 INSTALLING THE CLUTCH 1 Install clutch boss 1 lock washer clutch boss nut 2 2 Tigh...

Page 284: ...in stages and in a crisscross pattern 7 Install pull lever NOTE _ Install the pull lever with the mark facing towards the clutch cover T R 8 Nm 0 8 m kg 5 8 ft lb 8 Install clutch cover NOTE _ When in...

Page 285: ...hift shaft and stop per lever Remove the parts in the order listed Drive sprocket cover Refer to ENGINE 1 Throttle stop screw holder 1 2 Shift shaft cover 1 3 Shift shaft cover gasket 1 4 Dowel pin 2...

Page 286: ...ll shift shaft spring stopper 1 stopper lever spring 2 stopper lever 3 NOTE Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring onto the stopper le...

Page 287: ...t Q ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chap...

Page 288: ...12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 7 Drain pipe 1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Oil water pump as...

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

Page 290: ...the defec tive part s 2 Measure inner rotor to outer rotor tip clearance outer rotor to oil pump housing clearance oil pump housing to inner rotor and outer rotor clearance Out of specification Replac...

Page 291: ...relief valve 2 spring 3 O ring 4 Damage wear Replace the defective part s EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery...

Page 292: ...ousing screw NOTE _ When installing the inner rotor align the pin 1 in the oil pump shaft with the groove a in the inner rotor 2 3 Check oil pump operation Refer to CHECKING THE OIL PUMP Recommended l...

Page 293: ...R 10 Nm 1 0 m kg 7 2 ft lb EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket oil pan 1 oil level switch 2 engine oil drain bolt 3 WARNING _ Always use new copper washers NOTE _ Tighten the...

Page 294: ...er to ENGINE Cylinder head Refer to CYLINDER HEAD Pickup coil and pickup coil rotor Refer to PICKUP COIL Stator coil assembly Refer to GENERATOR Clutch housing and starter clutch idle gear Refer to CL...

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

Page 296: ...crankcase CAUTION _ Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make s...

Page 297: ...Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace CHECKING THE SPROCKET AND CHAINS 1 Check crankshaft sprocket...

Page 298: ...r crankshaft journal bear ings Do not apply sealant to within 2 3 mm of the crankshaft journal bearings 3 Install dowel pin Quick Gasket ACC 11001 05 01 4 Install crankshaft journal lower bearings 1 i...

Page 299: ...e oil Tighten the bolts in increasing numerical order Install washers on bolts 1 0 M9 105 mm bolts 1 0 M8 50 mm bolt L M8 60 mm bolt K M6 45 mm bolts J P R M6 50 mm bolt H M6 55 mm bolts A E M6 60 mm...

Page 300: ...ving the connecting rods and pistons Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Pi...

Page 301: ...so that it can be reinstalled in its original place 2 Remove piston pin clips 1 piston pin 2 piston 3 CAUTION _ Do not use a hammer to drive the piston pin out NOTE _ For reference during installation...

Page 302: ...ankcase NOTE _ Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place EAS00261 CHECKING THE CYLINDER AND PISTONS 1 Check piston wall cylinde...

Page 303: ...minimum of D2 D4 or D6 c Measure piston skirt diameter P with the micrometer a 5 mm from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calcula...

Page 304: ...der with the piston crown a 5 mm 0 20 in 3 Measure piston ring end gap Out of specification Replace the piston ring NOTE _ The oil ring expander spacer s end gap cannot be measured If the oil ring rai...

Page 305: ...diameter b Out of specification Replace the piston 4 Calculate piston pin to piston clearance Out of specification Replace the piston pin and piston as a set CHECKING THE BIG END BEARINGS 1 Measure cr...

Page 306: ...o the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c...

Page 307: ...120 WARNING When the nut is tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a t...

Page 308: ...g rod P1 and the crankshaft web P1 numbers are 4 and 1 respectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 2 5 1 2 2 black BIG END BEARING COLOR CODE 1 violet 0 white 1 blue 2...

Page 309: ...to the illustration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate piston piston rings cylinder with the recommended lubricant Recommended l...

Page 310: ...ith the other hand Make sure that the Y marks a on the con necting rods face towards the left side of the crankshaft Make sure that the characters b on both the connecting rod and connecting rod cap a...

Page 311: ...he specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified a...

Page 312: ...ft assembly Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Cr...

Page 313: ...urnal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION _ Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaf...

Page 314: ...the lower crankcase and assemble the crankcase halves NOTE _ Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until...

Page 315: ...and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are...

Page 316: ...shaft journal upper bearings 1 into the upper crankcase NOTE _ Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each cranks...

Page 317: ...s Removing the transmission shift drum assembly and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Stopper lever Refer to SHIFT SHAFT 1 Drive axle assembly 1 2...

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

Page 319: ...e main axle assembly Disassembly the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7...

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

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

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

Page 323: ...axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork cam follower 1 shift fork pawl 2 Bends...

Page 324: ...G THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure drive axle runout with a centering device and dial gauge 1 O...

Page 325: ...ft fork R shift fork L springs shift fork guide bars drive axle assembly NOTE _ Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C...

Page 326: ...Refer to SEATS and FUEL TANK in chapter 3 Air filter case and rubber cover Refer to AIR FILTER CASE in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Drive sprocket cover Re...

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

Page 328: ...diator cap opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pres...

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

Page 330: ...move the parts in the order listed Radiator assembly Refer to RADIATOR Exhaust pipe assembly Refer to ENGINE in chapter 5 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler ou...

Page 331: ...ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Bend the lock washer tab along a flat side...

Page 332: ...der seat and fuel tank Refer to SEATS and FUEL TANK in chapter 3 Air filter case and rubber cover Refer to AIR FILTER CASE in chapter 3 Throttle body assembly Refer to THROTTLE BODIES in chap ter 7 Co...

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

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

Page 335: ...ce a thermometer in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature 1 Thermometer 2 Water 3 Thermostat 4 Container Fully closed Fully open NOTE _...

Page 336: ...ing the thermo switch and temperature sender Replace any part that was dropped or sub jected to a strong impact EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1 Fill cooling system with the specified amo...

Page 337: ...water pump and oil pump are com bined into one unit oil water pump assembly It is not necessary to remove the impel ler shaft unless the coolant level is extremely low or coolant leaks from the oil p...

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

Page 339: ...the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE _ Do not scratch the impeller shaft EAS00473 CHECK...

Page 340: ...lubricate the water pump seal sur face with oil or grease NOTE _ Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 or Quick Gasket 2 to...

Page 341: ...ure impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION _ Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Impeller shaft ti...

Page 342: ...sure sensor 9 Throttle position sensor 0 Fuel injector A Catalytic converter B Crankshaft position sensor C Coolant temperature sensor D Spark plug E Cylinder identification sensor F Pressure regulato...

Page 343: ...B L W B G Y B G B R L W R W R B L O B GRAY GRAY GRAY F R L L B L B GRAY F R L G B G B GRAY F R L R B Y B R B R B GRAY F R L R L F Gy G Gy G D L W Y B L L Y W B L L W B B L L Y W B L BLACK BLACK Y L B...

Page 344: ...memory until a deletion operation is performed Engine trouble warning light indication and FI system operating conditions This control is effected when any one of the conditions listed below is prese...

Page 345: ...toward the open side for 3 seconds and then stop it Able Able 18 EXUP servo motor lock A lock EXUP servo motor is detected Perform the preventive control against motor locking Preform the lock releas...

Page 346: ...ment method in the troubleshooting details Repair Completion Checking the meter display Check whether the self diagnostic fault code num ber is shown after turning the main switch OFF once and then tu...

Page 347: ...isappear except the clock and trip indications Letters dlAG appear on the clock LCD 3 Using the SELECT button select either the CO adjustment mode which appears as CO or the diagnosis mode which appea...

Page 348: ...ensor 01 16 A stuck throttle position sensor is detected Stuck throttle position sensor Malfunction in ECU 01 17 EXUP servo motor potention circuit open or short circuit detected Open or short circuit...

Page 349: ...or or an open or short circuit is detected in the neutral switch Open or short circuit in wiring harness Defective speed sensor Malfunction in vehicle speed sensor detected unit Defective neutral swit...

Page 350: ...layed on the meter 06 Coolant temperature Displays the coolant temperature Check the temperature of the coolant Compare it to the value dis played on the meter 07 Vehicle speed pulse Displays the accu...

Page 351: ...the engine stop switch is ON turn it OFF once and then turn it back ON Check the operating sound of the injector five times with engine stop switch ON 39 Injector 4 After 1 second has elapsed from th...

Page 352: ...has been detected as a self diagnostic fault code 44 If multiple malfunctions have been detected different codes are displayed at 2 second intervals and this process is repeated 01 04 Displays the cy...

Page 353: ...nstated by starting the engine and operating it at idle Defective cylinder identification sensor Replace if defective 1 Connect the pocket tester DC 20 V to the cylinder identification sensor coupler...

Page 354: ...kshaft position sensor coupler as shown 3 Measure the crankshaft position sensor resistance 4 Is the crankshaft position sensor OK Open or short circuit in wiring harness Repair or replace if there is...

Page 355: ...tage 4 Is the intake air pressure sensor OK Reinstated by turn ing the main switch ON Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Bet...

Page 356: ...n ing the main switch ON Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Yel...

Page 357: ...he EXUP servomotor resistance 4 Is the EXUP servomotor OK Reinstated by turn ing the main switch ON Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between...

Page 358: ...ing the EXUP servomo tor perform this test within a few seconds of connecting the battery 5 Does the EXUP servomotor pulley turn Reinstated by turn ing the main switch ON It takes 120 sec onds at the...

Page 359: ...clogged kinked or pinched Atmospheric pressure sensor hose is clogged Repair or replace the sensor hose Reinstated by turn ing the main switch ON Defective intake air pressure sensor or atmo spheric p...

Page 360: ...ntake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 4 Is the intake air temperatu...

Page 361: ...pheric air pressure sensor OK Reinstated by turn ing the main switch ON Open or short circuit in wiring harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU co...

Page 362: ...an angle cut off switch approx 65 the voltage reading is 1 0 V to 4 0 V 5 Is the emergency stop switch OK Reinstated by turn ing the main switch ON however the engine cannot be restarted unless the ma...

Page 363: ...operating it at idle In case of multiple cylinder open or short circuit in lead make sure to turn ON and OFF the main switch after each time of crank ing Open or short circuit in lead wire Repair or r...

Page 364: ...any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Ignition coil primary side coupler Gray Green Main wiring harn...

Page 365: ...detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 Connected condition of speed sensor connec tor Inspect the coupler for any pins that may have pulled out Chec...

Page 366: ...el injection system relay is on Malfunction or open circuit in fuel injection sys tem relay Replace if defective 1 Disconnect the starting circuit cut off relay from the wire harness 2 Connect the poc...

Page 367: ...ty cylinder If there are mul tiple cylinders the number of the faulty cylinders appear alternately at 2 second intervals Replace ECU if defective Reinstated by turn ing the main switch ON Fault code N...

Page 368: ...is an open or short circuit Between sensor coupler and ECU coupler Yellow Red Yellow Red Black White Black White Reinstated by turn ing the main switch ON Connected condition of connector Inspect the...

Page 369: ...s an open or short circuit Between sensor coupler and ECU coupler Yellow Red Yellow Red Black White Black White Reinstated by turn ing the main switch ON Connected condition of connector Inspect the c...

Page 370: ...rder listed Seats fuel tank rubber sheet Refer to SEATS and FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Sub...

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

Page 372: ...pler 1 Disconnect 2 Intake air pressure sensor 1 Disconnect 3 Cylinder 1 injector coupler 1 Disconnect 4 Cylinder 2 injector coupler 1 Disconnect 5 Cylinder 3 injector coupler 1 Disconnect 6 Cylinder...

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

Page 374: ...1 Check injector Damage Replace CHECKING THE THROTTLE BODY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petrole...

Page 375: ...mity vac 2 onto the negative pressure hose from the pressure regulator d Connect the pressure gauge 3 and adapter 4 onto the fuel injection pipe e Install the fuel tank Refer to SEATS and FUEL TANK in...

Page 376: ...nect the throttle position sensor cou pler b Remove the throttle position sensor from the throttle body c Connect the pocket tester 1k to the throttle position sensor d Measure the maximum throttle po...

Page 377: ...from those specified 2 Adjust throttle position sensor angle a Connect the throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the throt tle position sensor c...

Page 378: ...ed exhaust gases is approximately 600 to 700 C 1 100 to 1 300 F EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions...

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

Page 380: ...ks damage Replace pipes Cracks damage Replace 2 Check reed valve 1 reed valve stopper reed valve seat Cracks damage Replace the reed valve 3 Measure reed valve bending limit a Out of specification Rep...

Page 381: ...coupler from the wire harness b Connect the pocket tester 1 to the AI system solenoid terminal as shown c Measure the AI system solenoid resistance d Out of specification Replace Tester positive probe...

Page 382: ...2 Front brake switch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuel injection system fuse 7 Main fuse 8 Neutral switch 9 Rear brake switch 0 Sidestand switch A Oil level switch B Radiator fan motor...

Page 383: ...3 Intake air pressure sensor 4 Lean angle cut off switch 5 Atmospheric pressure sensor 6 ECU 7 Starting circuit cut off relay 8 Turn signal relay 9 Speed sensor 0 Crankshaft position sensor A Cylinde...

Page 384: ...ket tester to 0 and to the 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch...

Page 385: ...to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 1 Main switch 2 Dimmer switch 3 Clutch switch 4 Horn...

Page 386: ...The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The m...

Page 387: ...other wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcoho...

Page 388: ...icate no continuity replace the bulb socket CHECKING THE LEDs The following procedures applies to all of the LEDs 1 Check LED for proper operation Improper operation Replace a Disconnect the meter ass...

Page 389: ...L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y B G B R L W R W R B L O B...

Page 390: ...er YM 03112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery...

Page 391: ...S The ignition system is OK 5 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil leads from the wire harness Connect the pocket tester 1...

Page 392: ...position sensor OK YES NO Replace the crankshaft position sensor 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK YES NO Replace the main switch...

Page 393: ...probe blue black 2 Continuity Positive tester probe blue black 2 Negative tester probe blue yellow 1 No continuity NOTE _ When you switch the positive and negative tester probes the readings in the ab...

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

Page 395: ...f relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor Wh...

Page 396: ...tion fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHAR...

Page 397: ...rom the coupler Connect the pocket tester 1 and bat tery 12 V to the starter relay coupler as shown Positive battery terminal red white 1 Negative battery terminal blue white 2 Positive tester probe r...

Page 398: ...Refer to CHECKING THE SWITCHES Is the clutch switch OK YES NO Replace the clutch switch 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES...

Page 399: ...Q ty Remarks Removing the starter motor Remove the parts in the order listed Rider seat Refer to SEATS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Left side cowling Refer to COWLINGS in ch...

Page 400: ...emarks Disassembling the starter motor Disassembly the parts in the order listed 1 Starter motor rear cover 1 2 Bearing 1 3 Starter motor yoke 1 4 O ring 2 5 Armature assembly 1 6 Brush 2 7 Brush hold...

Page 401: ...ator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Commutator wear limit 23 5 mm 0 93 in Mica undercut 1 5 mm 0 059 in 4 Measure armature assembly res...

Page 402: ...wear Replace the gear EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE _ Align the tab a on the brush seat with the slot b in the starter motor rear cover Brush spring force 5 28 7 92...

Page 403: ...CUIT DIAGRAM BLACK R Br L R Br L L Y L B L B L Y R B GRAY W W W ON OFF R W R W L W R W L W R R R R B B B B B R W R B R B R W W W W W R W B R Br L Br L L B R W L Y RED RED R R G 1 2 3 4 5 8 6 7 9 w 2 A...

Page 404: ...2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery...

Page 405: ...te 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 19 0 23 at 20 C 68 F Is the stator coil OK YES NO Replace the stator coil assembly 5 Wiring Check the wi...

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

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

Page 408: ...1 Main signal and headlight fuses Check the main signal and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signal and headlight fuses OK YES NO Replace the fuse...

Page 409: ...ay dimmer from the coupler Connect the pocket tester 1 and bat tery 12 V to the headlight relay dimmer coupler as shown Low beam Positive tester probe black blue 1 Negative tester probe black green 2...

Page 410: ...hen the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Headlight Positive tester probe black yellow 1 or black green 2 Negative tester probe black 3 High...

Page 411: ...thin specification YES NO This circuit is OK The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired 1 Tail brake light bulb and socket Check the tail brake l...

Page 412: ...in specification YES NO This circuit is OK The wiring circuit from the main switch to the auxiliary light connectors is faulty and must be repaired 1 License plate light bulb and socket Check the lice...

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

Page 414: ...ht U Neutral indicator light W Coolant temperature indicator light Y Turn signal indicator light L Z Turn signal indicator light R Oil level gauge _ Flasher relay b Multi function meter d Horn switch...

Page 415: ...YM 03112 1 Main ignition signaling and back up fuses Check the main ignition signaling and back up fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition signaling and ba...

Page 416: ...witch Does the horn sound NO YES Replace the horn The horn is OK 1 Tail brake light bulb and socket Check the tail brake light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKE...

Page 417: ...harness side as shown Positive tester probe brown 1 Negative tester probe ground Set the main switch to ON Measure the voltage DC 12 V on brown 1 at the turn signal relay coupler wire harness side Is...

Page 418: ...ight bulb and socket Check the neutral indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the neutral indicator light bulb and socket OK YES NO Replace the...

Page 419: ...evel gauge resis tanse Oil level gauge resistance 108 132 at 20 C 526 624 at 20 C Is the engine oil level gauge OK YES NO Replace the engine oil level gauge 3 Voltage Connect the pocket tester DC 20 V...

Page 420: ...pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe green white 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage DC...

Page 421: ...voltage within specification NO YES Replace the multi function meter 3 Speed sensor Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Positive tester probe whit...

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

Page 423: ...coolant temperature meter meter assembly fails to indicate when the engine is warm Pocket tester YM 03112 1 Main ignition and fan motor fuses Check the main and ignition fuses for con tinuity Refer t...

Page 424: ...y and must be replaced 5 Radiator fan motor relay Disconnect the radiator fan motor relay from the wire harness Connect the pocket tester 1 and bat tery 12 V to the radiator fan motor terminal as show...

Page 425: ...or for continuity at the temperatures indicated in the table Coolant temperature sensor resistance 0 C 32 F 5 21 6 37 k 80 C 176 F 0 29 0 35 k WARNING _ Handle the coolant temperature sensor with spec...

Page 426: ...3 B3 B2 W P L Y G W R L B L B B B B Gy B L B Gy R W Br R Br R R L Br R R W Br Br R W W R L O B Y R Y R Y L B G B R Y G B L L B B Y Y B R L L Y Gy Sb Sb Sb W Y P W P W B L L L L L W Y B L L B L W B G Y...

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

Page 428: ...ion system fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s 2 Battery Check the condition o...

Page 429: ...ve continuity between red and red blue YES NO Replace the starting circuit cut off relay 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester 1 to th...

Page 430: ...gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 C...

Page 431: ...ealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ri...

Page 432: ...nnections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder he...

Page 433: ...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...

Page 434: ...connected hose Damaged pipe Improperly connected pipe FUEL SYSTEM Throttle body ies Incorrect main jet setting Incorrect fuel level Damaged or loose throttle body joint Air filter Clogged air filter...

Page 435: ...or improperly installed left handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bea...

Page 436: ...Faulty battery Incorrectly adjusted rear brake light switch TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or f...

Page 437: ...el warning light T Oil level warning light U Neutral indicator light V Tachometer W Coolant temperature indicator light X High beam indicator light Y Turn signal indicator light L Z Turn signal indica...

Page 438: ...RD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G BLACK BLACK WIRE SUB LEAD 3 MAIN HARNESS F GRAY BLUE BLUE GRAY WIRE SUB LEAD 2 MAIN HARNESS E GRAY GRAY WIRE SUB LEAD 1 MAIN HARNESS D D COR...

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

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