Yamaha YZF-R1S Service Manual Download Page 402

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8-9

IGNITION SYSTEM

ELEC

Main switch

Fuse (main)

Battery

Starting circuit cut-off relay

Neutral switch

Sidestand switch

E.C.U.

Ignition coil #1

Ignition coil #2

Ignition coil #3

Ignition coil #4

Spark plug

Crankshaft position sensor

Cylinder identification sensor

Lean angle cut-off switch

Engine stop switch

Clutch switch

Fuse (ignition)

Summary of Contents for YZF-R1S

Page 1: ......

Page 2: ...3 by Yamaha Motor Corporation U S A First edition December 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 17 55 ...

Page 3: ...s policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual wh...

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

Page 5: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 6: ...FICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 FI 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS ...

Page 7: ... 7 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 11 ELECTRICAL SPECIFICATIONS 2 15 CONVERSION TABLE 2 18 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 23 LUBRICATION POINTS...

Page 8: ...STING THE VALVE CLEARANCE 3 11 SYNCHRONIZING THE THROTTLE BODIES 3 17 ADJUSTING THE EXHAUST GAS VOLUME 3 19 ADJUSTING THE ENGINE IDLING SPEED 3 21 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 22 CHECKING THE SPARK PLUGS 3 23 MEASURING THE COMPRESSION PRESSURE 3 24 CHECKING THE ENGINE OIL LEVEL 3 26 CHANGING THE ENGINE OIL 3 28 MEASURING THE ENGINE OIL PRESSURE 3 29 ADJUSTING THE CLUTCH CABLE FREE PLAY...

Page 9: ...ATING THE CABLES 3 61 LUBRICATING THE LEVERS AND PEDALS 3 61 LUBRICATING THE SIDESTAND 3 61 LUBRICATING THE REAR SUSPENSION 3 61 ELECTRICAL SYSTEM 3 62 CHECKING AND CHARGING THE BATTERY 3 62 CHECKING THE FUSES 3 67 REPLACING THE HEADLIGHT BULBS 3 69 ADJUSTING THE HEADLIGHT BEAMS 3 70 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS 4 1 REMOVING THE FRONT WHEEL 4 3 CHECKING THE FRONT WHEEL 4 3 CHECKIN...

Page 10: ...SEMBLING THE FRONT BRAKE CALIPERS 4 37 DISASSEMBLING THE REAR BRAKE CALIPER 4 38 CHECKING THE FRONT AND REAR BRAKE CALIPERS 4 39 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4 40 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4 42 FRONT FORK 4 44 FRONT FORK LEGS 4 44 REMOVING THE FRONT FORK LEGS 4 47 DISASSEMBLING THE FRONT FORK LEGS 4 48 CHECKING THE FRONT FORK LEGS 4 49 ASSEMBLING THE FR...

Page 11: ... 5 1 DRIVE SPROCKET 5 1 EXHAUST PIPE 5 2 LEADS AND HOSES 5 5 ENGINE 5 7 INSTALLING THE ENGINE 5 9 CAMSHAFT 5 11 CYLINDER HEAD COVER 5 11 CAMSHAFTS 5 13 REMOVING THE CAMSHAFTS 5 14 CHECKING THE CAMSHAFTS 5 15 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES 5 17 CHECKING THE TIMING CHAIN TENSIONER 5 17 INSTALLING THE CAMSHAFTS 5 19 CYLINDER HEAD 5 22 REMOVING THE CYLINDER HEAD 5...

Page 12: ... 52 CHECKING THE CLUTCH SPRINGS 5 53 CHECKING THE CLUTCH HOUSING 5 53 CHECKING THE CLUTCH BOSS 5 53 CHECKING THE PRESSURE PLATE 5 54 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 54 INSTALLING THE CLUTCH 5 54 SHIFT SHAFT 5 58 SHIFT SHAFT AND STOPPER LEVER 5 58 REMOVING THE SHIFT SHAFT 5 60 CHECKING THE SHIFT SHAFT 5 61 CHECKING THE STOPPER LEVER 5 61 INSTALLING THE SHIFT SHAFT 5 61 OIL PAN AND OIL ...

Page 13: ...RANKSHAFT DRIVE SPROCKET 5 93 CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5 93 INSTALLING THE CRANKSHAFT 5 96 TRANSMISSION 5 97 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 97 REMOVING THE TRANSMISSION 5 103 CHECKING THE SHIFT FORKS 5 103 CHECKING THE SHIFT DRUM ASSEMBLY 5 104 CHECKING THE TRANSMISSION 5 104 INSTALLING THE TRANSMISSION 5 105 CHAPTER 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RA...

Page 14: ...KING THE THROTTLE BODY JOINTS 7 39 CHECKING THE PRESSURE REGULATOR 7 40 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 40 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 41 CHECKING AND ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 43 CHECKING AND ADJUSTING THE THERMO WAX 7 45 AIR INDUCTION SYSTEM 7 46 AIR INJECTION 7 46 AIR CUT OFF VALVE 7 46 AIR INDUCTION SYSTEM DIAGRAMS 7 47 CHE...

Page 15: ...G SYSTEM 8 24 CIRCUIT DIAGRAM 8 24 TROUBLESHOOTING 8 25 LIGHTING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 CHECKING THE LIGHTING SYSTEM 8 31 SIGNALING SYSTEM 8 34 CIRCUIT DIAGRAM 8 34 TROUBLESHOOTING 8 36 CHECKING THE SIGNALING SYSTEM 8 36 COOLING SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 45 FUEL PUMP SYSTEM 8 48 CIRCUIT DIAGRAM 8 48 FUEL PUMP SYSTEM 8 49 TROUBLESHOOTING 8 50 ...

Page 16: ...4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 FAULTY LIGHTING OR 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 ...

Page 17: ...TORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 18: ...veled since they were last set to zero Sa fuel reserve tripmeter which shows the distance traveled since the fuel level warning light came on Sa stopwatch Sa clock Sa coolant temperature display San air intake temperature display Sa self diagnosis device Sa display brightness and shift timing indicator light control mode SBe sure to turn the key to ON before using the SELECT and RESET buttons Cloc...

Page 19: ...pwatch 2 Push the SELECT button to stop the stopwatch 3 Push the SELECT button again to reset the stopwatch Split time measurement 1 Push the RESET button to start the stopwatch 2 Push the RESET button to measure split times The colon will start flashing 3 Push the RESET button to display the final split time or push the SELECT button to stop the stop watch and display total elapsed time 4 Push th...

Page 20: ...have to cycle through all of its functions However if the key is turned to OFF or the engine is started before completing the procedure only the settings made be fore the SELECT button was last pushed will be applied SIn this mode the right display shows the current setting for each function except the shift timing indi cator light activity function To adjust the brightness of the multifunction me...

Page 21: ...unction can be set between 7000 r min and 15000 r min From 7000 r min to 12000 r min the indicator light can be set in increments of 500 r min From 12000 r min to 15000 r min the indicator light can be set in increments of 200 r min SBe sure to set the deactivation function to a higher engine speed than for the activation function otherwise the shift timing indicator light will remain deactivated ...

Page 22: ...disassembly clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function ...

Page 23: ...s are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways repl...

Page 24: ... Connect and disconnect sev eral times 3 Check Sall connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect Slead Scoupler Sconnector Make sure all connections are tight 5 Check Scontinuity with the pocket tester Pocket tester 90890 03112 YU 3112 SIf there is no continuity clean the terminals SWhen checking the wire harness perform steps 1 to 3 ...

Page 25: ...is tool is used to remove the piston pins Radiator cap tester 90890 01325 YU 24460 01 Adapter 90890 01352 YU 33984 Radiator cap tester Radiator cap tester adapter These tools are used to check the cooling system 90890 01403 YU 33975 Steering nut wrench This tool is used to loosen or tighten the steering stem ring nuts 90890 01423 YM 01423 Damper rod holder This tool is used to hold the damper rod ...

Page 26: ...90890 04019 YM 04019 Attachment 90890 04108 YM 01253 90890 04114 YM 4114 Valve spring compressor Valve spring compressor attachment These tools are used to remove or install the valve assemblies Middle driven shaft bearing driver 90890 04058 YM 4058 Mechanical seal installer 90890 04078 YM 33221 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water ...

Page 27: ...This tool is used to check the electrical sys tem Pivot shaft wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 Pivot shaft wrench Pivot shaft wrench adapter This tool is need to loosen or tighten the spacer bolt 90890 03132 YU 3112 Pocket tester This instrument is needed for checking the engine oil temperature Oil pressure gauge 90890 03153 YU 03153 Adapter 90890 03139 Oil pressu...

Page 28: ...eeded to remove and install the valve lifter 90890 03176 YM 03176 Fuel pressure adapter This tool is needed to measure fuel pres sure 90890 03153 YU 03153 Pressure gauge This tool is used to measure fuel pressure 90890 04143 YM 04143 Camshaft wrench This tool is used to hold and rotate the cam shaft sprocket ...

Page 29: ... height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 065 mm 8 13 in 720 mm 28 3 in 1 105 mm 43 5 in 835 mm 32 9 in 1 395 mm 54 9 in 135 mm 5 31 in 3 400 mm 133 9 in SSS SSS SSS SSS SSS SSS SSS Weight Wet with oil and a full fuel tank Maximum load except motorcycle 193 kg 425 lb USA 194 kg 428 lb CAL 202 kg 445 lb USA 201 kg 443 lb CAL SSS SSS ...

Page 30: ...g reserve Reserve only Premium unleaded gasoline only 18 L 3 96 Imp gal 4 76 US gal 3 4 L 0 75 Imp gal 0 90 US gal SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature Relief valve opening pressure Wet sump At 5_C 40_F or higher Yamalube 4 20W40 or SAE 20W40...

Page 31: ...ap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 51 L 2 21 Imp qt 2 65 US qt 108 X 137 kPa 1 08 X 1 37 kg cm2 1 0 X 1 3 bar 15 6 X 19 9 psi 380 mm 14 96 in 258 mm 10 2 in 24 mm 0 94 in 0 25 L 0 22 Imp qt 0 26 US qt Single suction centrifugal pump 65 43 25 32 1 181 SSS SSS SSS SSS SSS SSS SSS SSS 0 1...

Page 32: ...amshaft lobe dimensions Measurement A Measurement B Max camshaft runout Chain drive right 22 500 X 22 521 mm 0 8858 X 0 8867 in 22 459 X 22 472 mm 0 8842 X 0 8847 in 0 028 X 0 062 mm 0 0011 X 0 0024 in 32 85 X 32 95 mm 1 293 X 1 297 in 25 14 X 25 24 mm 0 990 X 0 994 in 30 75 X 30 85 mm 1 211 X 1 215 in 23 09 X 23 19 mm 0 909 X 0 913 in SSS SSS SSS SSS 32 75 mm 1 289 in 25 04 mm 0 986 in 30 65 mm 1...

Page 33: ... stem runout Valve seat width Intake Exhaust 23 4 X 23 6 mm 0 9213 X 0 9291 in 24 9 X 25 1 mm 0 9803 X 0 9882 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 5 X 0 9 mm 0 0197 X 0 0354 in 0 5 X 0 9 mm 0 0197 X 0 0354 in 3 975 X 3 990 mm 0 1565 X 0 1571 in 4 460 X 4 475 mm 0 1756 X 0 1762 in 4 000 X 4 012 mm 0 ...

Page 34: ... 32 7 mm 1 29 in 32 8 mm 1 29 in 145 9 X 167 9 N 14 88 X 17 12 kg 32 80 X 37 74 lb 164 1 X 188 9 N 16 73 X 19 26 kg 36 89 X 42 46 lb SSS SSS Clockwise Clockwise 37 3 mm 1 47 in 37 3 mm 1 47 in SSS SSS SSS SSS 2 5_ 1 7 mm 0 07 in 2 5_ 1 7 mm 0 07 in SSS SSS Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max out of round Forward inclined parallel 4 cylinder 77 0 mm 53 6 mm 3 03 2 ...

Page 35: ...4 X 0 0014 in 76 975 X 76 990 mm 3 0305 X 3 0311 in 5 mm 0 20 in 17 002 X 17 013 mm 0 6694 X 0 6698 in 0 5 mm 0 0197 in Intake side 16 991 X 17 000 mm 0 6689 X 0 6693 in 0 002 X 0 022 mm 0 0001 X 0 0009 in Barrel 0 90 2 75 mm 0 04 0 11 in 0 15 X 0 25 mm 0 0059 X 0 0098 in 0 030 X 0 065 mm 0 0012 X 0 0026 in Taper 0 80 2 75 mm 0 03 0 11 in 0 30 X 0 45 mm 0 0118 X 0 0177 in 0 020 X 0 055 mm 0 0008 X...

Page 36: ... 0 09 mm 0 0035 in SSS Crankshaft Width A Width B Max runout C Big end side clearance D Crankshaft journal to crankshaft journal bearing clearance Bearing color code 55 20 X 56 60 mm 2 17 X 2 23 in 298 8 X 300 7 mm 11 76 X 11 84 in SSS 0 160 X 0 262 mm 0 0063 X 0 0103 in 0 014 X 0 037 mm 0 0006 X 0 0015 in 0 White 1 Blue 2 Black 3 Brown 4 Green SSS SSS 0 03 mm 0 0012 in SSS 0 10 mm 0 0039 in SSS ...

Page 37: ...tity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity Wet multiple disc Outer pull rack and pinion pull Cable operation Left hand operation 10 X 15 mm 0 39 X 0 59 in Purple 2 9 X 3 1 mm 0 114 X 0 122 in 7 Green 2 9 X 3 1 mm 0 114 X 0 112 in 1 2 9 X 3 1 mm 0 114 X 0 112 in 1 1 9 X 2 1 mm 0 07 X 0 08 in 8 SSS 52 5 mm 2 07 in 6 SSS SSS SSS SSS SSS SSS 2 8 ...

Page 38: ...SS SSS SSS 0 08 mm 0 0032 in 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Max shift fork guide bar bending Shift drum Guide bar SSS SSS 0 10 mm 0 0039 in Air filter type Oil coated paper element SSS Fuel pump Pump type Model manufacturer Output pressure Electrical 5PW DENSO 294 kPa 2 94 kg cm2 2 94 bar 42 6 psi SSS SSS SSS Throttle position sensor Resistance Output voltage at idle 4 9...

Page 39: ...m 0 04 in 0 5 mm 0 02 in Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 0 X 198 lb 90 X 202 kg 198 X 445 lb High speed riding Min tire tread depth Tubeless 120 70 ZR17 M C 58W Pilot POWER C MICHELIN D218FL DUNLOP 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi SSS SSS SSS SSS SSS SSS SSS 1 6 mm 0 06 in Rear t...

Page 40: ...4 mm 0 55 in 30 1 mm and 27 mm 1 19 in and 1 06 in SSS SSS SSS SSS SSS 4 0 mm 0 16 in 0 1 mm 0 004 in 0 5 mm 0 02 in 0 5 mm 0 02 in SSS SSS Rear brake Brake type Operation Recommended fluid Brake pedal freeplay Brake discs Diameter thickness Min thickness Max deflection Brake pad lining thickness inner Brake pad lining thickness outer Master cylinder inside diameter Caliper cylinder inside diamete...

Page 41: ...the fork spring Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Telescopic fork Coil spring oil damper 120 mm 4 72 in 236 5 mm 9 31 in 100 mm 3 937 in 222 5 mm 8 76 in 8 83 N mm 0 90 kg mm 50 42 lb in 0 X 120 mm 0 X 4 7244 in 43...

Page 42: ...ting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 65 mm 2 56 in 173 5 mm 6 83 in 163 5 mm 6 44 in 83 4 N mm 8 50 kg mm 476 21 lb in 0 X 65 mm 0 00 X 2 56 in No 1 200 kPa 12 kg cm2 12 bar 171 psi 1 4 9 20 17 1 20 12 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SS...

Page 43: ...turer Normal output Stator coil resistance color A C magneto F4T850 MITSUBISHI 14 V 560 W at 5 000 r min 0 14 X 0 18 Ω at 20_C 68_F W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semi conductor short circuit FH011AA SHINDENGEN SSS SSS No load regulated voltage Rectifier capacity Withstand voltage 14 3 X 15 1 V 50 A 100 V SSS SSS SSS Battery Battery type Battery voltage ca...

Page 44: ...YAMAHA 0 9 kW 10 8 mm 0 43 in 5 28 X 7 92 N 538 X 808 g 18 99 X 28 48 oz 0 0090 X 0 0110 Ω at 20_C 68_F 24 5 mm 0 96 in 1 5 mm 0 06 in SSS SSS SSS 3 6 mm 0 14 in SSS SSS 23 5 mm 0 93 in SSS Starter relay Model manufacturer Amperage Coil resistance 2768079 A JIDECO 180 A 4 18 X 4 62 Ω at 20_C 68_F SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil resistance Plane ...

Page 45: ...rage quantity Main fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse odometer and clock Reserve fuse 50 A 1 15 A 1 25 A 1 10 A 1 15 A 1 15 A 2 10 A 1 25 A 15 A 10 A 1 SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 46: ...10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 ftSlb 4 3 11 22 40 61 94 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSIO...

Page 47: ... water pump assembly sprocket Bolt M6 1 15 1 5 11 Water pump Bolt M6 2 12 1 2 8 7 Thermostat cover Nut M6 2 10 1 0 7 2 Thermostat inlet pipe Bolt M6 1 10 1 0 7 2 Oil cooler Bolt M20 1 63 6 3 46 Engine oil drain bolt Bolt M14 1 43 4 3 31 Oil pipe Bolt M6 2 10 1 0 7 2 Oil strainer Bolt M6 3 10 1 0 7 2 Oil delivery pipe Bolt M6 3 10 1 0 7 2 Oil filter union bolt Bolt M20 1 70 7 0 51 Oil filter M20 1 ...

Page 48: ...ler and rear frame Bolt M8 2 23 2 3 17 Muffler cover Bolt M6 2 10 1 0 7 2 Crankcase Stud bolt M10 10 8 0 8 5 8 Crankcase main journal Bolt M9 10 See NOTE 2 Crankcase Bolt M6 10 12 1 2 8 7 Crankcase Bolt M8 1 24 2 4 17 Crankcase Bolt M8 5 24 2 4 17 Generator rotor cover Bolt M6 4 12 1 2 8 7 Generator rotor cover Bolt M8 3 22 2 2 16 Drive sprocket cover Bolt M6 2 10 1 0 7 2 Drive sprocket cover Bolt...

Page 49: ...2 2 0 2 1 5 Coolant temperature sensor M12 1 18 1 8 13 Cylinder identification sensor Bolt M6 1 8 0 8 5 7 Atmospheric pressure sensor Screw M5 2 7 0 7 5 0 Crankshaft position sensor Bolt M6 1 10 1 0 7 2 Oil level switch Bolt M6 2 10 1 0 7 2 1 First tighten the bolts to approximately 19 Nm 1 9 mSkg 14 ftSlb with a torque wrench following the tightening order 2 Retighten the bolts 67 Nm 6 7 mSkg 48 ...

Page 50: ...2 22 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence ...

Page 51: ...olant reservoir tank and frame M6 5 0 5 3 6 Engine mount front left and right M10 45 4 5 33 Engine mount rear upper M10 51 5 1 37 Engine mount rear under M10 51 5 1 37 Engine mount rear adjust bolt M16 7 0 7 5 1 Catalyst pipe stay and frame M10 44 4 4 32 Clutch cable lock nut engine side M8 7 0 7 5 1 Main frame and rear frame M10 41 4 1 30 Throttle cable adjust nut throttle body side M6 5 0 5 3 6 ...

Page 52: ...ly 52 Nm 5 2 mSkg 38 ftSlb with a torque wrench then loosen the ring nut completely 2 Retighten the lower ring nut to specification Refer to INSTALLING THE ENGINE in chapter 5 1 Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm 9 1 mSkg 65 8 ftSlb 2 In the order from the pinch bolt 2 pinch bolt 1 pinch bolt 2 tighten each bolt to 20 Nm ...

Page 53: ... pump housing Oil strainer Clutch pull rod Oil water pump drive sprocket and washer Clutch thrust plate Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Crankcase mating su...

Page 54: ... upper and lower Relay arm connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting pint and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and spring Shift shaft joint Front wheel oil seal ...

Page 55: ...2 27 1 Radiator fan 2 Radiator 3 Water pump COOLING SYSTEM DIAGRAMS SPEC EAS00033 COOLING SYSTEM DIAGRAMS ...

Page 56: ...2 28 1 Thermostat 2 Radiator cap 3 Radiator 4 Oil cooler COOLING SYSTEM DIAGRAMS SPEC ...

Page 57: ...2 29 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART ...

Page 58: ...2 30 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch EAS00034 LUBRICATION DIAGRAMS ...

Page 59: ...2 31 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 8 Relief valve LUBRICATION DIAGRAMS SPEC ...

Page 60: ...2 32 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe LUBRICATION DIAGRAMS SPEC ...

Page 61: ...2 33 1 Main axle 2 Oil delivery pipe 3 Drive axle LUBRICATION DIAGRAMS SPEC ...

Page 62: ...2 34 1 Cylinder head 2 Crankshaft LUBRICATION DIAGRAMS SPEC ...

Page 63: ...ther location of the right and left relays is acceptable B The lead should not stretch too much C Make sure to insert the coupler and boot to the stay 1 hole D The speedometer lead should not be strained E To the stay 1 hole F Connect after passing over the upper side of the duct 1 Ground lead 2 Meter lead 3 Stay 1 4 Auxiliary light lead right 5 Headlight lead 6 Auxiliary light lead left 7 Console...

Page 64: ...y 1 at the positioning white tape section There should be no slack when clamping Point the tip of the clamp excessive part to the front side of the vehicle Fasten the head light lead with a clamp M Feed a lead wire through the U shape cutout of the console pan el ...

Page 65: ...o get along the front side of the main switch after passing it through the guide B Pass the main switch lead through the guide wire C Pass the left handlebar switch lead through the guide wire D Point the tip of the band exces sive part to the rear side of the vehicle and cut the surplus sec tion Clamp it to the outer tube E Clamp the section between 0 and 20 mm 0 and 0 79 in from the split of the...

Page 66: ...of the clamp and guide wire to the front fork outer tube Cut the tip of the clamp leaving 2 to 4 mm 0 08 X 0 16 in Point the binding part to the external part of the vehicle Clamp it to the outer tube I Cut the tip leaving 2 to 4mm 0 08 X 0 16 in ...

Page 67: ...s sive part to the front side of the vehicle Fasten the right handle bar switch lead with a clamp B To the wire harness C The clutch cable positioning guide should be above the upper end of the clamp Fasten the clutch cable with a clamp Refer to D Position relation between the clamp and guide M CABLE ROUTING SPEC 1 Wire harness 2 Crankshaft position sensor lead 3 Heat protector 4 Right handlebar s...

Page 68: ...J Pass the right handlebar switch lead between the frame and heat protector K Coolant reservoir tank drain hose should cross with the speed sensor lead under the swingarm bracket Route the coolant reservoir tank drain hose over the up side of the vehicle L Pass the rear brake light switch lead between the swingarm bracket and coolant reservoir tank M Release the tip of the clamp and install it to ...

Page 69: ...ner of the vehicle than the washer position after routing them between the frame and radiator stay Align the clamp position with the taping sections of leads Point the tip of the clamp surplus section to the down front side of the vehicle What the clamp fastens at this stage are the handlebar switch and main switch leads B Pass the main switch lead and left handlebar switch lead be tween the frame...

Page 70: ...with a clamp K Route the water hose so that it is placed at the outermost position finally after routing other leads and hoses in the guide L To the coolant reservoir tank CABLE ROUTING SPEC M There should be no exposure of bared conductors due to the dis placement of the tube N Route the coolant reservoir tank drain hose so that it is routed at the innermost position to each hose and lead O Can b...

Page 71: ...h lead 21 Sidestand switch lead 22 Throttle body lead 23 Coolant reservoir tank drain hose 24 Fuel tank drain hose 25 Cover 7 26 Radiator fan motor lead left 27 Radiator fan motor lead right 28 Wire harness 29 Pipe 3 30 Frame 31 Coolant reservoir tank hose 32 Thermo stat assembly breather hose CABLE ROUTING SPEC 1 Heat protector 2 Crankshaft position sensor lead 3 Neutral switch lead 4 Ground lead...

Page 72: ...een three protrusions of the pipe the first and second parts from the ve hicle front Point the tip of the clamp excessive part to the in side of the vehicle D To the vehicle right side diagram E To the engine F Clamp the lead between three protrusions of the pipe the in side and outside of the vehicle G Point the tip of the clamp exces sive part to the inside of the ve hicle H All hoses and leads ...

Page 73: ...ss on the tip of the clamp af ter passing the leads through it R Insert the tail brake light lead to the rear frame hole S Insert the clamp from the vehicle front to the rear side and fasten each lead coupler and onion head to the fender rib and then point the tip of the clamp exces sive part to the upper side of the vehicle T Hold down the clamp tips after passing each lead U Make sure to positio...

Page 74: ...ery negative lead A C magneto lead and starter motor lead with a clamp AA To the speed sensor BB Insert the wire harness wrap ping clamp to the hole of the frame CC After passing the lead be tween the wire harness and starter motor leads fastening by the clamp should be can celled and route the lead un der the idle remote controller CABLE ROUTING SPEC HH Insert the wire harness wrap ping clamp to ...

Page 75: ...can be inserted in any direction NN Route each lead higher than the frame plate pass it to the inside of the vehicle from the hole Leads should be routed in random order Clamp can be inserted in any direction OO The hoses should not be lo cated higher than the throttle body side cap over the up side of the vehicle CABLE ROUTING SPEC ...

Page 76: ...sections are per fectly equipped A B C A Install the lip of O ring facing up ward B Install the part pointing the white paint part of the hose to the left side of the vehicle C Any direction of the clip grip can be accepted D Install the clip grip as specified in the drawing E Install the part pointing the white paint part of the hose to the left side of the vehicle F Point the clip grip to the le...

Page 77: ... down side of the vehicle B Insert the hose so that its tip of the nipple does not protrude C Install the part pointing the white paint mark to the left side of the vehicle D Insert the hose until it reaches the R bottom of the pipe E To the throttle body CABLE ROUTING SPEC for CAL 1 Clip 2 Clamp 3 Rivet 4 Roll over valve assembly 5 Balance pipe 6 Pipe 4 7 Canister hose 8 Canister assembly 9 Canis...

Page 78: ...on See page 3 17 21 S Check and adjust engine idle speed and syn chronization Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 6 Exhaust system See page 3 35 S Check for leakage S Tighten if necessary S Replace gasket s if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 7 Evaporative emission control system For California only S Check control system for damage S Replace if necessary Ǹ Ǹ 8 Air induction system See page 7 46 S Check the air cut off valve reed val...

Page 79: ...eakage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 19 Rear suspension link pivots See page 4 71 S Check operation S Correct if necessary Ǹ Ǹ 20 Engine oil See page 3 26 28 S Change warm engine before draining Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 21 Engine oil filter cartridge See page 3 28 S Replace Ǹ Ǹ Ǹ 22 Cooling system S Check hoses for cracks or damage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 22 Cooling system See page 3 37 38 39 S Cha...

Page 80: ...Job Part Q ty Remarks 1 2 Removing the seats Rider seat Passenger seat 1 1 Remove the parts in the order listed For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb SEATS CHK ADJ EAS00039 SEATS ...

Page 81: ...nk over flow hose Fuel tank breather hose Fuel tank Fuel tank cover Fuel pump 2 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 4 Nm 0 4 mSkg 2 9 ftSlb 4 Nm 0 4 mSkg 2 9 ftSlb FUEL TANK CHK ADJ EAS00040...

Page 82: ...been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remain ing in it Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Sfuel tank Do not set the fuel tank down so that the installa tion surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position REMOVING THE FUEL PU...

Page 83: ...asket SInstall the fuel pump as shown in the illustra tion STighten the fuel pump bolts in stages in a criss cross pattern and to the specified torque INSTALLING THE FUEL TANK 1 Install Sfuel hose Sfuel return hose Sfuel hose connector cover When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position otherwise the fuel hose will no...

Page 84: ... cowing front cover Frame side cover Frame side panel Headlight panel Front cowling Rear view mirror Windshield Air intake duct Air intake duck mount 2 2 2 2 1 2 2 2 1 2 1 2 2 Remove the parts in the order listed Refer to SEATS Disconnect For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 16 Nm 1 6 mSkg 12 ftSlb COWLINGS CHK ADJ COWLINGS FRONT COWLING AN...

Page 85: ...pler Rear turn signal light lead coupler Tail brake light License plate bracket assembly Rear cowling lower 1 1 4 1 1 1 Remove the parts in the order listed Refer to SEATS Refer to EXHAUST PIPE in chapter 5 Disconnect Disconnect For installation reverse the removal procedure 4 Nm 0 4 mSkg 2 9 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb COWLINGS CHK ADJ REAR COWLING ...

Page 86: ...with a screwdriver then pull the fastener out INSTALLATION 1 Install Sside cowlings Srear cowling To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cowling and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 87: ...nsor Air filter case cover Air filter Funnel Air filter case Air induction system hose Crankcase breather hose 1 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to SEATS Refer to FUEL TANK Disconnect Disconnect Disconnect For installation reverse the removal procedure 2 Nm 0 2 mSkg 1 4 ftSlb 3 4 Nm 0 34 mSkg 2 5 ftSlb AIR FILTER CASE CHK ADJ AIR FILTER CASE ...

Page 88: ... TDC on the compression stroke 1 Remove Srider seat Refer to SEATS Sfuel tank Refer to FUEL TANK Sair filter case Refer to AIR FILTER CASE Sbottom cowlings Sside cowlings Refer to COWLINGS Sthrottle body assembly Refer to THROTTLE BODIES in chapter 7 Sair cut off valve Refer to AIR INDUCTION SYSTEM in chapter 7 Sradiator Sradiator fan motor Refer to RADIATOR in chapter 6 2 Remove Signition coils S...

Page 89: ...ion stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 3 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at...

Page 90: ...rag to prevent the valve pad from falling into the crankcase SMake a note of the position of each valve lifter 2 and valve pad 1 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table Valve pad thickness range Available valve pads Nos 120 X 240 1 20 0 0472 X 2 40 mm 0 0945 in 25 thicknesses in 0 05 mm 0 002 in increments SThe thickness a of each ...

Page 91: ...sect is the new valve pad number The new valve pad number is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lift er 2 SLubricate the valve pad with molybdenum dis ulfide grease SLubricate the valve lifter with molybdenum dis ulfide oil SThe valve lifter must t...

Page 92: ...lobes and camshaft journals SFirst install the exhaust camshaft SAlign the camshaft marks with the camshaft cap marks STurn the crankshaft counterclockwise several full turns to seat the parts g Measure the valve clearance again h If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained ...

Page 93: ... 215 220 225 230 235 240 0 96 X 1 00 200 205 210 215 220 225 230 235 240 1 01 X 1 05 205 210 215 220 225 230 235 240 1 06 X 1 10 210 215 220 225 230 235 240 1 11 X 1 15 215 220 225 230 235 240 1 16 X 1 20 220 225 230 235 240 1 21 X 1 25 225 230 235 240 1 26 X 1 30 230 235 240 1 31 X 1 35 235 240 1 36 X 1 40 240 EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215...

Page 94: ...le bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand 2 Remove Srider seat Refer to SEATS Sfuel tank Refer to FUEL TANK 3 Remove Ssynchronizing hoses 1 4 Install Svacuum gauge 1 onto the synchronizing hose Sdigital tachometer near the spark p...

Page 95: ...e body 3 as standard adjust throttle bodies 1 2 and 4 using the air screws 1 SAfter each step rev the engine two or three times each time for less than a second and check the synchronization again SIf the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization Vacuum pre...

Page 96: ... at the flange of the throttle grip 3 X 5 mm 0 12 X 0 20 in 13 Install Ssynchronizing hoses Sfuel tank Refer to FUEL TANK Srider seat Refer to SEATS ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the carbon monoxide density to standard and then adjust the exhaust gas 1 Turn the main switch to OFF and engine stop switch ON 2 While keeping the SELECT and RESET buttons pressed simultaneously turn ON...

Page 97: ...der appears on the clock LCD RESET button decrement SELECT button increment 6 Excute the selection of the cylinder by simul taneously pressing the SELECT and RE SET buttons for approximately 2 seconds 7 After selecting the adjustment cylinder change the Co adjustment volume by pressing the SELECT and RESET but tons The Co adjustment volume appears on the trip LCD RESET button decrement SELECT butt...

Page 98: ...Sdigital tachometer near the spark plug 3 Check Sengine idling speed Out of specification Adjust Engine idling speed 1 150 X 1 250 r min 4 Adjust Sengine idling speed a Turn the idle adjusting screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is increased Direction Engine idling speed is decreased 5 Adjust Sthrottle cable free play Refer ...

Page 99: ...of the throttle grip 3 X 5 mm 0 12 X 0 20 in 2 Adjust Sthrottle cable free play Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased c Tighten the locknut After adjusting the throttle cable free play start the engin...

Page 100: ...k plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal ling into the cylinders 4 Check Sspark plug type Incorrect Change Spark plug type manufacturer CR9EK NGK 5 Check Selectrode 1 Damage wear Replace the spark plug Sinsulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Sspark plug with a spark plug cleaner ...

Page 101: ...gs Refer to COWLINGS EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl inders Insufficient compression pressure will result in a loss of performance 1 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Signition coils Sspark plugs Be...

Page 102: ...2 14 80 bar 210 5 psi Maximum 1 660 kPa 16 60 kg cm2 16 60 bar 236 11 psi a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug leads before cranking the engine The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm2 1 bar 14 22 psi c If the com...

Page 103: ... s wear or damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly defective Repair 6 Install Sspark plug 7 Install Signition coils EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface SPlace the motorcycle on a suitable stand SMake sure the motorcycle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Ch...

Page 104: ...AT 15_C 60_F or lower B Yamalube 4 10W30 or SAE 10W30 type SE motor oil Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled ...

Page 105: ... 3 5 Remove Sengine oil drain bolt 1 along with the gasket 6 Drain Sengine oil completely from the crankcase 7 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench 90890 01426 YU 38411 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil Make sure the O...

Page 106: ...filter cartridge replacement 3 1 L 2 73 Imp qt 3 28 US qt 11 Install Sengine oil filler cap Sbottom cowlings Refer to COWLINGS 12 Start the engine warm it up for several min utes and then turn it off EAS00077 MEASURING THE ENGINE OIL PRESSURE 1 Check Sengine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min ute...

Page 107: ...er 90890 03139 6 Measure Sengine oil pressure at the following conditions Engine oil pressure 230 kPa 2 3 kg cm2 2 3 bar 32 71 psi Engine speed Approx 5 000 r min Engine oil temperature 100_C 212_F Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity the oil pressure may fluctuate when measuring The following data should be used only as a referenc...

Page 108: ...8 Install Sbottom cowlings Refer to COWLINGS EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Sclutch cable free play a Out of specification Adjust Clutch cable free play at the end of the clutch lever 10 X 15 mm 0 39 X 0 59 in 2 Adjust Sclutch cable free play Handlebar side a Turn the adjusting dial 1 in direction b or c until the specified clutch cable free play is ob tained Direction Clutc...

Page 109: ...s increased Direction Clutch cable free play is decreased c Tighten the locknuts Lock nut 7Nm 0 7 mSkg 5 1 ftSlb EAS00086 REPLACING THE AIR FILTER ELEMENT 1 Remove Srider seat Refer to SEATS Sfuel tank Refer to FUEL TANK 2 Remove Sair filter case cover 1 3 Check Sair filter element 1 Damage Replace Replace the air filter element at periodic inter vals of 40 000 km travel The air filter needs more ...

Page 110: ...mance and possible overheat ing When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 5 Install Sfuel tank Refer to FUEL TANK Srider seat Refer to SEATS EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses 1 Remove Srider seat Refer to SEATS Sfuel ta...

Page 111: ... pinched by the fuel tank EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Srider seat Refer to SEATS Sfuel tank Refer to FUEL TANK 2 Check Scrankcase breather hose 1 Cracks damage Replace Loose connection Connect properly Make sure the crankcase breather hose is routed correctly 3 Install Sfuel tank Refer to FUEL TANK Srider seat Refer to SEATS To install the fuel tank check that the breath...

Page 112: ... Cracks damage Replace Sgaskets 4 Exhaust gas leaks Replace 2 Check Stightening torque Exhaust pipe nut 5 20 Nm 2 0 mSkg 14 ftSlb Exhaust pipe and exhaust valve pipe bolt 6 10 Nm 1 0 mSkg 7 2 ftSlb Catalyst pipe assembly bolt 7 20 Nm 2 0mSkg 14 ftSlb Catalyst pipe assembly and muffler bolt 8 20 Nm 2 0 mSkg 14 ftSlb Muffler cover 9 10 Nm 1 0 mSkg 7 2 ftSlb Install the EXUP cable in parallel without...

Page 113: ...XUP cable free play at the EXUP valve pulley a b Maximum EXUP cable free play at the EXUP valve pulley Less than 4 mm 0 16 in 5 Adjust SEXUP cable free play a Turn the main switch to ON b Check the EXUP pulley position c Projection of the EXUP pulley position is be tween 1 and 2 d Loosen the both locknuts 3 e Turn the both adjusting nuts 4 in or out f Tighten the both locknuts 6 Install SEXUP valv...

Page 114: ...el mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level SAdding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant SUse only distilled water However if dis tilled water is not available soft water may be used 3 S...

Page 115: ...radiator 1 Sradiator inlet hose 2 Sradiator outlet hose 3 Soil cooler 4 Soil cooler inlet hose 5 Soil cooler outlet hose 6 Swater jacket joint 7 Swater jacket joint inlet hose 8 Swater pump inlet pipe 9 Swater pump outlet pipe 10 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install Sside cowlings Sbottom cowling Refer to COWLINGS ...

Page 116: ...radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his sing sound has stopped press down on the radiator...

Page 117: ...ty ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 51 L 2 21 Imp qt 2 65 US qt Coolant reservoir capacity 0 25 L 0 22 Imp qt 0 26 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care SIf coolant splashes in your eyes thorough ly wash them with water and consu...

Page 118: ... contact with painted surfaces immediately wash them with wa ter SDo not mix different types of antifreeze 13 Install Sradiator cap 14 Fill Scoolant reservoir tank with the recommended coolant to the maxi mum level mark a 15 Install Scoolant reservoir cap 16 Start the engine warm it up for several min utes and then stop it 17 Check Scoolant level Refer to CHECKING THE COOLANT LEV EL Before checkin...

Page 119: ... is the smallest SAfter adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjust ing dial SA soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce in loss of ...

Page 120: ... through the hole d c Tighten the locknut 1 to specification Locknut 16 Nm 1 6 mSkg 12 ftSlb A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an acci...

Page 121: ...cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and...

Page 122: ...e braking effect starts 1 Check Srear brake light operation timing Incorrect Adjust 2 Adjust Srear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction Brake light comes on later EAS00122 CHE...

Page 123: ... a 0 5 mm 0 02 in b 1 0 mm 0 04 in A Front brake B Rear brake EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Sbrake hose 1 Cracks damage wear Replace A Front B Rear 2 Check Sbrake hose clamp 2 Loose Tighten the clamp bolt 3 Hold the motorcycle upright and apply the brake several times 4 Check Sbrake hose Brak...

Page 124: ...f bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Shydraulic brake system a Fill the brake fluid reservoir to the proper lev el with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 A ...

Page 125: ...he brake fluid reservoir to the proper lev el with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake operation After bleeding air the brake fluid may ooze around the thread section of each bleed screw This phenomenon does not show the leakage but the brake fluid that has been accumulated in the thread of screw while bleedi...

Page 126: ...hin the specified limits 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of drive chain 3 Check Sdrive chain slack a Out of specification Adjust Drive chain slack 25 X 35 mm 0 98 X 1 38...

Page 127: ...d proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the motorcycle is used in dusty areas This motorcycle has a drive chain with small rubber O rings between each side plate Steam cleaning high pressure washing certain sol vents and the use of a coarse brush can dam age these O rings Therefore use only kero sene to clean the drive chain Wipe the drive ...

Page 128: ...p the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Supper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4 4 Adjust Ssteering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5 Set the torque wrench at...

Page 129: ...ghten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Supper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4 6 Measure Ssteering head tension Make sure all of the cables a...

Page 130: ...bove procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check Sinner tube 1 Damage scratches Replace Soil seal 2 ...

Page 131: ...torcycle so that there is no danger of it falling over Spring preload SGrooves are provided to indicate the ad justment position SNever go beyond the maximum or mini mum adjustment positions 1 Adjust Sspring preload a Turn the adjusting bolt 1 in direction a or b Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting position...

Page 132: ...Maximum 1 clicks in direction b with the adjusting screw fully turned in direction a Compression damping Never go beyond the maximum or minimum adjustment positions 1 Adjust Scompression damping a Turn the adjusting screw 1 in direction a or b Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum ...

Page 133: ...1 Adjust Sspring preload a Adjust the spring preload with the special wrench and extension bar included in the owner s tool kit b Turn the adjusting ring 1 in direction a or b c Align the desired position on the adjusting ring with the stopper 2 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting positions Minimum 1 Standa...

Page 134: ...ion b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction a Compression damping Never go beyond the maximum or minimum adjustment positions 1 Adjust Scompression damping a Turn the adjusting screw 1 in direction a or b Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Mi...

Page 135: ...otorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 193 kg 425 lb 194 kg 428 lb for CAL Maximum load 202 kg 445 lb 201 kg 443 lb for CAL Cold tire pressure Front Rear Up to 90 kg load 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi 90 kg X maximum load 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 290 ...

Page 136: ...e sure the wheel rim band and tube are centered in the wheel groove SPatching 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 re placement A Tire B Wheel Tube wheel Tube tire only T beless wheel Tube or tubeless Tubeless wheel tire After extensive tests the tires listed below have been approved ...

Page 137: ...ntil they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done For tires with a direction of rotation mark 1 SInstall the tire with the mark pointing in the direction of wheel rotation SAlign the mark 2 with the valve installation point EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Chec...

Page 138: ...cate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease EAS00172 LUBRICATING THE SIDESTAND...

Page 139: ...electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL SSkin Wash with water SEyes Flush with water for 15 minutes and get immediate medical attention INTERNAL SDrink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion SThis is a sealed battery Never remove the sealing ...

Page 140: ...ttery terminals 1 Remove Srider seat Refer to SEATS 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Pocket tester 90890 03112 YU 3112 Positive tester probe positive battery terminal Negative tester probe negative batt...

Page 141: ...ive bat tery lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure the battery charger lead clips are in full contact with the battery terminal and that they are not sho...

Page 142: ...n checking steps If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the battery unused fo...

Page 143: ...rging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Set the charging time at 20 hours maximum YES NO NOTE Voltage should be ...

Page 144: ...ion Connect properly 9 Lubricate Sbattery terminals Recommended lubricant Dielectric grease 10 Install Srider seat Refer to SEATS EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Sfront cowling inner panel left Refer to COWLINGS Srider seat Refer to SEATS 2 Check Sfu...

Page 145: ... Fuses Amperage rating Q ty Main 50 A 1 Fuel injection system 15 A 1 Headlight 25 A 1 Signaling system 10 A 1 Ignition 15 A 1 Backup fuse odometer and clock 10 A 1 Radiator fan motor 15 A 2 Reserve 25 A 15 A 10 A 1 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause...

Page 146: ...nect Sheadlight bulb cover 1 Sheadlight coupler 2 A high beam B low beam 2 Remove Sheadlight bulb holder 1 A high beam B low beam 3 Remove Sheadlight bulb Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 4 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder ...

Page 147: ...ver high beam Sheadlight bulb coupler low beam 7 Connect Sheadlight coupler high beam Sheadlight cover low beam EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Remove Sfront cowling inner panels Refer to COWLINGS 2 Adjust Sheadlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headli...

Page 148: ...ont wheel axle Collar left and right Front wheel Front brake disc left and right 2 2 2 2 4 1 1 2 1 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated For installation reverse the removal procedure NOTE 35 Nm 3 5 mSkg 25 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb 91 Nm 9 1 mSkg 66 ftSlb 20 Nm 2 0 mSkg 13 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb 18 Nm 1 8 mSk...

Page 149: ... CHAS Order Job Part Q ty Remarks Disassembling the front wheel Oil seal left and right Wheel bearing left and right Spacer 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 EAS00518 ...

Page 150: ...er to FRONT BRAKE CALIPERS Do not apply the brake lever when removing the brake calipers 3 Elevate Sfront wheel Place the motorcycle on a suitable stand so that the front wheel is elevated 4 Loosen Sfront wheel axle pinch bolt 5 Remove Sfront wheel axle bolt Sfront wheel axle Sfront wheel EAS00525 CHECKING THE FRONT WHEEL 1 Check Swheel axle Roll the wheel axle on a flat surface Bends Replace Do n...

Page 151: ...e Swheel bearings New Soil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing...

Page 152: ...ont brake disc deflec tion turn the handlebars to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 06 in be low the edge of the brake disc 3 Measure Sbrake disc thickness Measure the brake disc thickness at a few different locations Out of specification R...

Page 153: ...ification replace the brake disc EAS00545 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs 1 Lubricate Swheel axle Soil seal lips Recommended lubricant Lithium soap based grease 2 Lift the wheel up between the fork legs 3 Insert the wheel axle Install the tire and wheel with the mark 1 point ing in the direction of wheel rotation 4 Lower the front wheel so that it is ...

Page 154: ...e adjusted SAdjust the front wheel static balance with the brake discs installed 1 Remove Sbalancing weight s 2 Find Sfront wheel s heavy spot Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the whee...

Page 155: ...urn the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Sfront wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 156: ...ock Right adjusting block Rear wheel Brake caliper bracket 1 2 2 1 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen For installation reverse the removal procedure NOTE 22 Nm 2 2 mSkg 16 ftSlb 27 Nm 2 7 mSkg 20 ftSlb 150 Nm 15 mSkg 108 ftSlb REAR WHEEL AND BRAKE DISC CHAS EAS00551 REAR WHEEL AND BRAKE DISC REA...

Page 157: ...rocket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel 1 1 2 1 1 1 6 1 Remove the parts in the order listed For installation reverse the disassembly procedure 100 Nm 10 mSkg 72 ftSlb 30 Nm 3 0 mSkg 22 ftSlb EAS00560 REAR BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 158: ... DISC CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Collar Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 ...

Page 159: ...he motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sbrake caliper 1 Do not depress the brake pedal when removing the brake caliper 3 Loosen Slocknut 1 Sadjusting bolt 2 4 Remove Swheel axle nut 1 Swheel axle Srear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Sleft collar 1 Srear wheel drive hub 2 Srear wheel drive hub...

Page 160: ... Measure Sradial wheel runout Slateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Srear wheel drive hub 1 Cracks damage Replace Srear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Srear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace th...

Page 161: ...0 mSkg 72 ftSlb Tighten the self locking nuts in stages and in a crisscross pattern EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate Swheel axle Swheel bearings Soil seal lips Recommended lubricant Lithium soap based grease 2 Tighten Swheel axle nut Sbrake caliper bolts front rear EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE SAfter replacing the tire wheel or both the rear wheel static balance s...

Page 162: ... pad spring Brake pad Bleed screw 1 1 2 1 1 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers For installation reverse the removal procedure NOTE 5 Nm 0 5 mSkg 3 6 ftSlb 35 Nm 3 5 mSkg 25 ftSlb 6 Nm 0 6 mSkg 4 3 ftSlb FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 163: ...ake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring 1 1 1 4 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure 5 Nm 0 5 mSkg 3 6 ftSlb 27 Nm 2 7 mSkg 20 ftSlb 3 Nm 0 3 mSkg 2 2 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 22 Nm 2 2 mSkg 16 ftSlb REAR BRAKE PADS ...

Page 164: ...must be disassembled drained cleaned properly filled and bled after reas sembly SNever use solvents on internal brake com ponents SUse only clean or new brake fluid for clean ing brake components SBrake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately SAvoid brake fluid coming into contact with the eyes as it can cause serious injury F...

Page 165: ...s not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove Sbrake hose holder 1 Sbrake caliper 2 2 Remove Sbrake pad clips 1 Sbrake pad pin 2 Sbrake pad spring 3 3 Remove Sbrake pads 1 along with the brake pad shims 4 Measure Sbrake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 0 5 mm 0 02 in ...

Page 166: ...caliper with your finger c Tighten the bleed screw Bleed screw 5 Nm 0 5 mSkg 3 6 ftSlb d Install a new brake pad shim onto each new brake pad Install the brake pad spring pointing a toward the bleed screw e Install new brake pads and a new brake pad spring 6 Install Sbrake pad pins Sbrake pad clips Sbrake caliper 7 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake f...

Page 167: ...screw plug 1 Sbrake pad pin 2 Sbrake caliper 3 Sbrake pad spring 2 Remove Sbrake pads 1 along with the brake pad shims 2 3 Measure Sbrake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 1 0 mm 0 04 in 4 Install Sbrake pad shims onto the brake pads Sbrake pads Sbrake pad spring Always install new brake pads brake pad shims and a brake pad spring as a set ...

Page 168: ...hten the bleed screw Bleed screw 5 Nm 0 5 mSkg 3 6 ftSlb d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Srear brake caliper front rear brake caliper rear Sbrake pad pin Sscrew plug 6 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check Sbrake pedal operation Sof...

Page 169: ...lder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever Front brake switch connector Union bolt 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Drain Refer to CHANGING THE BRAKE FLUID in chapter 3 Disconnect 3 8 Nm 0 38 mSkg 2 7 ftSlb 1 2 Nm 0 12 mSkg 0 9 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 30 Nm 3 0 mSkg 22 ftSlb EAS00584 FRONT BRAKE MASTER CYLINDE...

Page 170: ...2 13 14 Copper washer Brake hose Brake master cylinder bracket Brake master cylinder Front brake light switch 2 1 1 1 1 For installation reverse the removal procedure 3 8 Nm 0 38 mSkg 2 7 ftSlb 1 2 Nm 0 12 mSkg 0 9 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 30 Nm 3 0 mSkg 22 ftSlb ...

Page 171: ... Remarks Disassembling the front brake master cylinder Brake master cylinder kit Bleed screw Brake master cylinder body 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 6 Nm 0 6 mSkg 4 3 ftSlb EAS00585 ...

Page 172: ...Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint Bush Union bolt Copper washer Brake hose Brake master cylinder 1 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE BRAKE FLUID in chapter 3 For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 18 Nm 1 8 mSkg 13 ftSlb EAS00586 REAR BRAKE MASTER CYLIND...

Page 173: ...Job Part Q ty Remarks Disassembling the rear brake master cylinder Brake master cylinder kit Hose joint Bush Brake master cylinder body 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 ...

Page 174: ... 3 Sbrake hose 4 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove Sbrake master cylinder bracket Sbrake master cylinder assembly 4 Remove Sdust boot Scirclip EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove Sunion bolt 1 Scopper washers 2 Sbrake hose 3 To collect any remaining brake fluid place a container under t...

Page 175: ...der Damage scratches wear Replace Sbrake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check Sbrake master cylinder kit Damage scratches wear Replace A Front B Rear 3 Check Sbrake fluid reservoir 1 Cracks damage Replace Sbrake fluid reservoir diaphragm 2 Cracks damage Replace A Front B Rear 4 Check Sbrake hoses Cracks damage wear Repla...

Page 176: ...nder kit Scirclip New Sdust boot 2 Install Sbrake master cylinder 1 SInstall the brake master cylinder holder with the UP mark a facing up SAlign the end of the brake master cylinder holder with the punch mark b on the right han dlebar SFirst tighten the upper bolt then the lower bolt There should be 2 X 2 5 mm 0 08 X 0 10 in for clearance between the right handlebar switch and the brake master cy...

Page 177: ...ds may cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fl...

Page 178: ...o BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install Sbrake master cylinder kit Scirclip Sdust boot 2 Install Scopper washers New Sbrake hoses Sunion bolt Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake master cylinder make sure the brake pipe ...

Page 179: ...oes not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check Sbrake fluid level Below the minimum level mark a Add the r...

Page 180: ...ose brake caliper 1 2 1 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal procedure NOTE 6 Nm 0 6 mSkg 4 3 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 35 Nm 3 5 mSkg 25 ftSlb EAS00613 FRONT BRAKE CALIPERS ...

Page 181: ...ke pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 2 1 1 2 4 8 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers For assembly reverse the disassembly procedure NOTE 1 2 3 4 5 6 7 5 Nm 0 5 mSkg 3 6 ftSlb EAS00615 ...

Page 182: ...uid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 For installation reverse the removal procedure 30 Nm 3 0 mSkg 22 ftSlb 27 Nm 2 7 mSkg 20 ftSlb 22 Nm 2 2 mSkg 16 ftSlb EAS00616 REAR BRAKE CALIPER ...

Page 183: ...ke pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw 1 1 2 4 1 1 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 5 Nm 0 5 mSkg 3 6 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 3 Nm 0 3 mSkg 2 2 ftSlb EAS00617 ...

Page 184: ...d of the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake caliper piston seals 2 a Secure the brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper SNever try to pry out the brake caliper pis tons SDo not loosen the bolts 3 c Remove ...

Page 185: ...to a container and pump out the brake fluid carefully 2 Remove Sbrake caliper piston 1 Sbrake caliper piston seals 2 a Secure the brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the piston from the brake caliper SCover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake cali...

Page 186: ...as sembled 1 Check Sbrake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Sbrake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Sbrake caliper body 3 Cracks damage Replace the brake cali per assembly Sbrake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake ca...

Page 187: ...vents on internal brake com ponents as they will cause the piston seals to swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake pads Sbrake pad spring Sbrake pad pin 2 Install Sbrake caliper 1 Scopper washers New Sbrake hose 2 Sunion bolt 3 Sbrake hose holder Proper brake hose routing is essential to in su...

Page 188: ...nce SWhen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check Sbrake fluid lev...

Page 189: ...nal brake com ponents as they will cause the piston seals to swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper 1 front rear Sbrake pad pin Sscrew plug Scopper washers New Sbrake hose 2 Sunion bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTIN...

Page 190: ...nce SWhen refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check Sbrake fluid lev...

Page 191: ...olt Front fork leg 1 1 1 1 2 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT AND REAR BRAKES Refer to COWLINGS in chapter3 Loosen Loosen Loosen Loosen For installation reverse the removal procedure 6 Nm 0 6 mSkg 4 3 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 26 Nm 2 6 mSkg 19 ftSlb 23 Nm 2 3 mSkg 17 ftSlb FRONT FORK CHAS EAS00647 FRONT FORK FRO...

Page 192: ...justing rod Nut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The following the procedure applies to both of the front fork legs NOTE 1 2 3 4 5 6 7 8 9 10 23 Nm 2 3 mSkg 17 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 23 Nm 2 3 mSkg 17 ftSlb EAS00648 ...

Page 193: ...emarks Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube 1 1 1 1 1 1 For assembly reverse the disassembly procedure 11 12 13 14 15 16 23 Nm 2 3 mSkg 17 ftSlb 15 Nm 1 5 mSkg 11 ftSlb 23 Nm 2 3 mSkg 17 ftSlb ...

Page 194: ...it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Remove Sfront wheel Sfront brake caliper Refer to FRONT WHEEL AND BRAKE DISCS 3 Remove SSide Cowlings Refer to COWLINGS in chapter 3 Shandlebar 4 Loosen Shandlebar pinch bolt 1 Supper bracket pinch bolt 2 Scap bolt 3 Sunder bracket pinch bolt 4 Before loosening the upper and under bracket pinch bolts sup...

Page 195: ... 5 between the nut 3 and the spacer 2 Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 YM 01434 Use the side of the rod holder that is marked B c Loosen the nut d Remove the cap bolt e Remove the rod holder and fork spring com pressor The fork spring is compressed f Remove the spacer and nut 2 Drain Sfork oil Stroke the damper rod 1 several times while draining the fork oil 3 Rem...

Page 196: ...lowing procedure applies to both of the front fork legs 1 Check Sinner tube 1 Souter tube 2 Bends damage scratches Replace Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Sspring free length a Out of specification Replace Spring free length 236 5 mm 9 31 in Limit 231 8 mm 9 13 in 3 Check Sdamper rod 1 Damage wear Replace Obstruction Blow out all of the oi...

Page 197: ...1 Damage wear Replace EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs SMake sure the oil levels in both front fork legs are equal SUneven oil levels can result in poor han dling and a loss of stability SWhen assembling the front fork leg be sure to replace the following parts outer tube bushing oil seal dust seal Before assembling the front fo...

Page 198: ...f the inner tube Be careful not to damage the inner tube 2 Lubricate Sinner tube s outer surface Recommended lubricant Suspension oil 01 or equivalent 3 Tighten Sdamper rod assembly bolt 1 LOCTITE While holding the damper rod assembly with the damper rod holder 2 tighten the damper rod assembly bolt Damper rod holder 90890 01423 YM 01423 4 Install Sdust seal 1 Soil seal clip 2 Soil seal 3 Swasher ...

Page 199: ...th fork oil SBefore 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 SOil seal 1 with the fork seal driver 2 Fork seal driver 90890 01442 YM 01442 6 Install Soil seal clip 1 Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install Sdust seal 1 with the fork seal driver weight 2 Fork seal driv...

Page 200: ...l Suspension oil 01 or equivalent Front fork leg oil level from the top of the outer tube with the outer tube fully compressed and without the fork spring 76 mm 2 99 in SWhile filling the front fork leg keep it upright SAfter filling slowly pump the front fork leg up and down to distribute the fork oil 10 Install Snut 1 Sfork spring 2 Sspacer 3 Sdamper adjusting rod 4 Scap bolt 5 a Remove the rod ...

Page 201: ...0890 01434 YM 01434 f Remove the rod puller and adapter g Install the nut 1 and position it as specified b Distance b 11 mm 0 43 in h Set the cap bolt distance c to specification Distance c 13 mm 0 51 in i Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt j Hold the cap bolt and tighten the nut to speci fication Nut 15 Nm 1 5 mSkg 11 ftSlb k Remove the rod holder a...

Page 202: ...legs 1 Install Sfront fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Sunder bracket pinch bolt 1 Scap bolt 2 Shandlebar pinch bolt 3 Supper bracket pinch bolt 4 Make sure the brake hoses are routed prop erly 3 Adjust Sspring preload Srebound damping Scompression damping Refer to ADJUSTING TH...

Page 203: ...r switch Clutch cable holder Brake fluid reservoir tank Brake master cylinder bracket 1 1 2 1 1 1 1 1 2 1 2 1 1 1 1 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Disconnect Disconnect 113 Nm 11 3 mSkg 82 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 11 Nm 1 1 mSkg 8 0 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 3 8 Nm 0 38 mSkg 2 7 ftSlb 3 8 Nm 0 38 mSkg 2 ...

Page 204: ...bracket Left handlebar Right handlebar 1 1 2 2 2 1 1 1 1 For assembly reverse the disassembly procedure 113 Nm 11 3 mSkg 82 ftSlb 17 Nm 1 7 mSkg 12 ftSlb 11 Nm 1 1 mSkg 8 0 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 3 8 Nm 0 38 mSkg 2 7 ftSlb 3 8 Nm 0 38 mSkg 2 7 ftSlb 3 8 Nm 0 38 mSkg 2 7 ftSlb 13 Nm 1 3 mSkg 9 4 ftSlb 26 Nm 2 6 mSkg 19 ftSlb 17 Nm 1 7 mSkg 12 ...

Page 205: ...d gradually push the grip off the handlebar 3 Remove Sthrottle cable housing 1 Sthrottle grip 2 While removing the throttle cable housing pull back the rubber cover 3 EAS00669 CHECKING THE HANDLEBARS 1 Check Sleft handlebar 1 Sright handlebar 2 Bends cracks damage Replace Do not attempt to straighten bent handle bars as this may dangerously weaken them EAS00674 INSTALLING THE HANDLEBARS 1 Stand th...

Page 206: ...hen the lower bolt SAlign the mating surfaces of the brake master cylinder holder with the punch mark a in the right handlebar SThere should be 2 mm 0 08 in of clearance between the right handlebar switch and the brake master cylinder holder 4 Install Sthrottle grip Sthrottle cable housing 1 Sthrottle cables Align the projection a on the throttle cable housing with the hole b in the right handleba...

Page 207: ...r adhesive has fully dried 8 Adjust Sclutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 X 15 mm 0 39 X 0 59 in 9 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 X 5 mm 0 12 X 0 20 in CHECKING THE STEERING...

Page 208: ...er bolt Lock washer Upper ring nut 2 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to COWLINGS in chapter 3 Refer to FRONT FORK Disconnect For installation reverse the removal procedure 38 Nm 0 38 mSkg 2 75 ftSlb 113 Nm 11 3 mSkg 82 ftSlb 52 Nm 5 2 mSkg 38 ftSlb 18 Nm 1 8 mSkg 13 ftSlb 1st 2nd 23 Nm 2 3 mSkg 17 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 7 Nm ...

Page 209: ...ing inner race Upper bearing Lower bearing Dust seal Bearing outer race 1 1 1 1 2 1 1 1 2 For assembly reverse the disassembly procedure 38 Nm 0 38 mSkg 2 75 ftSlb 113 Nm 11 3 mSkg 82 ftSlb 52 Nm 5 2 mSkg 38 ftSlb 18 Nm 1 8 mSkg 13 ftSlb 1st 2nd 23 Nm 2 3 mSkg 17 ftSlb 23 Nm 2 3 mSkg 17 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 17 Nm 1 7 mSkg 12 ftSlb ...

Page 210: ... steering nut wrench 2 Steering nut wrench 90890 01403 YU 33975 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash Sbearings Sbearing races Recommended cleaning solvent Kerosene 2 Check Sbearings 1 Sbearing races 2 Damage pitting Replace 3 Replace Sbearings Sbearing races a Remove the bearing races 1 from the steer ing head pipe w...

Page 211: ...er seal 4 Check Supper bracket Slower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate Supper bearing Slower bearing Sbearing races Recommended lubricant Lithium soap based grease 2 Install Slower ring nut 1 Srubber washer 2 Supper ring nut 3 Slock washer 4 Refer to CHECKING THE STEERING HEAD in chapter 3 3 Install Supper bracket Ss...

Page 212: ...Oil seal bearing collar Collar self locking nut bolt Connecting arm Oil seal bearing collar Relay arm 1 1 1 1 1 1 1 1 6 3 3 1 1 1 2 2 1 1 1 Remove the parts in the order listed Refer to EXHAUST PIPE in chapter 5 For installation reverse the removal procedure 92 Nm 9 2 mSkg 67 ftSlb 44 Nm 4 4 mSkg 32 ftSlb 44 Nm 4 4 mSkg 32 ftSlb 44 Nm 4 4 mSkg 32 ftSlb REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 RE...

Page 213: ...rber or gas cylinder SDo 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 SDo not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORBE...

Page 214: ...ar wheel is elevated 2 Remove Sbottom cowling Refer to COWLINGS in chapter 3 Sservo motor Refer to EXHAUST PIPE in chapter 5 3 Remove Srear shock absorber assembly lower bolt 1 Srelay arm to swingarm bolt 2 While removing the rear shock absorber as sembly lower bolt hold the swingarm so that it does not drop down 4 Remove Srear shock absorber assembly upper bolt 1 Srear shock absorber assembly Rai...

Page 215: ...Damage wear Replace Sdust seals Damage wear Replace Sbolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Sspacers Sbearings Recommended lubricant Lithium soap based grease 2 Install Srear shock absorber assembly SWhen installing the rear shock absorber as sembly lift up the swingarm SInstall the connecting arm front bolt from the right 3 Tighten Srear s...

Page 216: ... Brake hose holder Pivot shaft nut washer Pivot shaft 1 2 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL AND BRAKE DISC Refer to REAR SHOCK ABSORBER ASSEMBLY Refer to ENGINE REMOVAL in chapter 5 Refer to EXHAUST PIPE in chapter 5 Refer to EXHAUST PIPE in chapter 5 28 Nm 2 8 mSkg 20 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 105 Nm 10 5 mSkg 76 ftSlb 2 Nm 0 2 mSkg...

Page 217: ...12 13 Swingarm Drive chain Dust cover Drive chain guide Spacer Bearing 1 1 2 1 1 2 For installation reverse the removal procedure 28 Nm 2 8 mSkg 20 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 105 Nm 10 5 mSkg 76 ftSlb 2 Nm 0 2 mSkg 1 4 ftSlb 16 Nm 1 6 mSkg 12 ftSlb ...

Page 218: ...olt hold the swingarm so that it does not drop down 3 Measure Sswingarm side play Sswingarm vertical movement a Measure the tightening torque of the pivot shaft nut Pivot shaft nut 105 Nm 10 5 mSkg 76 ftSlb b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm sid...

Page 219: ... falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove Sdrive chain with the drive chain cutter Only cut the drive chain if it or the swingarm is to be replaced EAS00707 CHECKING THE SWINGARM 1 Check Sswingarm Bends cracks damage Replace 2 Check Spivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot sh...

Page 220: ...Sbearings 3 Soil seals 4 Damage pitting Replace 7 Check Scollars 5 Damage scratches Replace EAS00709 CHECKING THE DRIVE CHAIN 1 Measure Sten link section a of the drive chain Out of specification Replace the drive chain Ten link drive chain section limit maximum 150 1 mm 5 91 in SWhile measuring the ten link section push down on the drive chain to increase its tension SMeasure the length between d...

Page 221: ...High pressure methods could force dirt or water into the drive chain s in ternals and solvents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Don t soak drive chain in kerosine more them ten minutes O ring is damage by kerosine 4 Check SO rings 1 Damage Replace the drive chain Sdrive chain rollers 2 Damage wear Replace t...

Page 222: ...ket EAS00711 INSTALLING THE SWINGARM 1 Lubricate Sbearings Sspacers Sdust covers Spivot shaft Recommended lubricant Lithium soap based grease 2 Install Sswingarm Spivot shaft 1 Spivot shaft nut 2 3 Install Srear shock absorber assembly Srear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and INSTAL LING THE REAR WHEEL 4 Adjust Sdrive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK...

Page 223: ...et cover Drive sprocket nut Lock washer Drive sprocket Plate 2 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Loosen For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 85 Nm 8 5 mSkg 61 ftSlb 7 Nm 0 7 mSkg 5 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb ENGINE ENG ENGINE ENGINE DRIVE SPROCKET ...

Page 224: ... valve pipe gasket Exhaust valve pipe assembly Catalyst pipe assembly Gasket Muffler Gasket 1 2 1 4 1 1 1 1 2 2 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 23 Nm 2 3 mSk...

Page 225: ...or EXUP servo motor bracket Protector 2 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 23 Nm 2 3 mSkg 17 ftSlb ENGINE ENG ...

Page 226: ...lley Collar Plate Spring Housing Gasket Shaft arm Exhaust valve pipe EXUP pulley bracket 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 7 Nm 0 7 mSkg 5 ftSlb ...

Page 227: ... negative lead Battery positive lead 1 1 Disconnect the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to THROTTLE BODIES in chapter 7 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to OIL COOLER in chapter 6 Refer to AIR INDUCTION SYSTEM in chapter 7 Refer to STARTING SYSTEM in chapter 7 ENGINE ENG LEADS AND HOSES ...

Page 228: ...ctor Neutral switch connector Speed sensor coupler Cylinder identification sensor coupler 1 2 1 1 1 1 1 1 First disconnect the negative battery lead and then the positive battery lead For connecting reverse the disconnec tion procedure Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect For installation reverse the removal procedure CAUTION ENGINE ENG ...

Page 229: ... Left front engine mounting bolt Lower self locking nut Lower engine mounting bolt Upper self locking nut Upper engine mounting bolt 1 1 1 1 1 1 1 1 Remove the parts in the order listed Place a suitable stand under the frame and engine NOTE 51 Nm 5 1 mSkg 37 ftSlb 51 Nm 5 1 mSkg 37 ftSlb 45 Nm 4 5 mSkg 33 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 45 Nm 4 5 mSkg 33 ftSlb ENGINE ...

Page 230: ... bolt Engine 2 1 Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts For installation reverse the removal pro cedure NOTE 51 Nm 5 1 mSkg 37 ftSlb 51 Nm 5 1 mSkg 37 ftSlb 45 Nm 4 5 mSkg 33 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 45 Nm 4 5 mSkg 33 ftSlb ...

Page 231: ...ing nuts Lubricate the lower and upper engine mounting bolts threads with lithium soap based grease 4 Install Sleft front engine mount bolt 1 temporary tighten 5 Install Sengine mount collar inside 1 Sengine mount collar outside 2 Sright front engine mount bolt 3 temporary tighten 6 Tighten Sengine mounting adjust bolts Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the e...

Page 232: ... wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 7 Tighten Supper self locking nut 1 Slower self locking nut 2 First tighten the lower self locking nut and then tighten the upper self locking nut 8 Tighten Sleft front engine mounting bolt 1 9 Tighten Sright front engine mounting bolt 1 ...

Page 233: ...g Cylinder head cover Cylinder head cover gasket 4 4 1 1 Remove the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Refer to THROTTLE BODIES in chapter 7 Refer to RADIATOR in chapter 3 Refer to AIR INDUCTION SYSTEM in chapter 7 13 Nm 1 3 mSkg 9 4 ftSlb 8 Nm 0 8 mSkg 5 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CAMSHAFT ENG EAS00194 CAMSHAFT CYLINDER HEAD COVER ...

Page 234: ...er Job Part Q ty Remarks 5 6 7 Timing chain guide top side Cylinder identification sensor O ring 1 1 1 For installation reverse the removal procedure 13 Nm 1 3 mSkg 9 4 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 8 Nm 0 8 mSkg 5 7 ftSlb ...

Page 235: ... camshaft Camshaft sprocket 4 1 1 3 6 3 6 1 1 2 Remove the parts in the order listed Refer to CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR Loosen Refer to REMOVING THE CAMSHAFTS For installation reverse the removal procedure During removal the dowel pins may still be connected to the camshaft caps NOTE 10 Nm 1 0 mSkg 7 2 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb...

Page 236: ... sion stroke align the T mark a on the pick up rotor with the crankcase mating surface b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Scamshaft sprocket bolts 1 Camshaft wrench 90890 04143 4 Remove Stiming chain tensioner 1 SO ring 5 Remove Scamshaft caps 1 Sdowel pins To prevent damage to the cylinder head camshafts or camshaft caps l...

Page 237: ...e discoloration pitting scratches Re place the camshaft 2 Measure Scamshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 32 85 X 32 95 mm 1 293 X 1 297 in Limit 32 75 mm 1 289 in b 25 14 X 25 24 mm 0 990 X 0 994 in Limit 25 04 mm 0 986 in Exhaust camshaft a 30 75 X 30 85 mm 1 211 X 1 215 in Limit 30 65 mm 1 207 in b 23 09 X 23 1...

Page 238: ...1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps STighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out SDo not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Camshaft cap bolt 10 Nm 1 0 mSkg 7 2 ftSlb d Remove the camshaft caps and then mea sure the width of the Plas...

Page 239: ... set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check Stiming chain guide exhaust side 1 Stiming chain guide intake side 2 Stiming chain guide top side 3 Damage wear Replace the defective part s CHECKING THE TIMING CHAIN TENSIONER 1 Remove Stiming chain tensioner housing 1 Stiming chain tensioner rod 2 Stiming chain tensioner spring 3 Squeeze the timing chain tensioner clip ...

Page 240: ...tensioner rod 3 When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2 make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2 Otherwise the timing chain tensioner rod 3 may run off c Hook the clip 4 to the timing chain tensioner rod 3 Hook the timing chain tensioner rod pin 5 to the center of...

Page 241: ...mporarily tightened Install the camshaft sprockets as a illustration 3 Install Sexhaust camshaft 1 Sintake camshaft 2 with the camshaft sprockets temporarily tightened Make sure the punch mark a faces up 4 Install Sdowel pins Sexhaust camshaft caps Sintake camshaft caps SMake sure each camshaft cap is installed in its original place SMake sure the arrow mark a on each cam shaft cap points towards ...

Page 242: ...ed evenly or damage to the cylinder head camshaft caps and camshafts will result SDo not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 6 Tighten Scamshaft sprocket bolts 1 Camshaft wrench 90890 04143 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 7 Align Sc...

Page 243: ...wise 10 Check S T mark a Make sure the T mark on the pickup rotor is aligned with the crankcase mating sure face b Scamshaft punch mark c Make sure the punch mark c on the cam shaft is aligned with the camshaft cap arrow mark d Out of alignment Adjust Refer to the installation steps above 11 Measure Svalve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 1...

Page 244: ...el pin Coolant pipe O ring Thermo wax out let hose 1 1 2 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS For installation reverse the removal procedure 18 Nm 1 8 mSkg 13 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 19 Nm 1 9 mSkg 14 ftSlb 67 Nm 6 7 mSkg 48 ftSlb 1st 2nd 10 Nm 1 0 mSkg 7 2 ftSlb CYLINDER HEAD ENG EAS00221 CYLINDER HEAD ...

Page 245: ...scraper Do not use a sharp instrument to avoid damag ing or scratching Sspark plug bore threads Svalve seats 2 Check Scylinder head Damage scratches Replace 3 Measure Scylinder head warpage Out of specification Resurface the cylin der head Maximum cylinder head warpage 0 10 mm 0 0039 in a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit i...

Page 246: ...ns 3 Install Scylinder head Pass the timing chain through the timing chain cavity 4 Tighten Scylinder head nuts 1 X 10 1st 2nd Scylinder head bolts 11 12 SFirst tighten the nuts 1 X 10 to approximate ly 19 Nm 1 9 mSkg 14 ftSlb with a torque wrench and then tighten the 67 Nm 6 7 mSkg 48 ftSlb SLubricate the cylinder head nuts with engine oil STighten the cylinder head nuts in the proper tightening ...

Page 247: ...nder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide 12 12 24 12 12 12 12 12 12 Remove the parts in the order listed Refer to CYLINDER HEAD EAS00236 VALVES AND VALVE SPRINGS ...

Page 248: ...ter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 16 8 8 8 8 8 8 For installation reverse the removal procedure VALVES AND VALVE SPRINGS ENG ...

Page 249: ...lled in their original place 2 Check Svalve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 3 Remove Svalve cotters 1 Remove the valve cotters by compressing the valve spring with the...

Page 250: ...lve stem diameter B Out of specification Replace the valve guide Valve stem to valve guide clearance Intake 0 0010 X 0 0037 mm 0 0004 X 0 0015 in Limit 0 08 mm 0 0032 in Exhaust 0 025 X 0 052 mm 0 0010 X 0 0020 in Limit 0 10 mm 0 0039 in 2 Replace Svalve guide To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100_C 212_F in an oven a Remove the ...

Page 251: ...liminate Scarbon deposits from the valve face and valve seat 4 Check Svalve face Pitting wear Grind the valve face Svalve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Svalve margin thickness a Out of specification Replace the valve Valve margin thickness 0 5 X 0 9 mm 0 0197 X 0 0354 in Limit 0 5 mm 0 02 in 6 Measure Svalve stem runout Out o...

Page 252: ... X 1 1 mm Intake 0 0354 X 0 0433 in Exhaust 0 9 X 1 1 mm Exhaust 0 0354 X 0 0433 in Limit 1 6 mm 0 06 in a Apply Mechanic s blueing dye 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 Where the valve seat and valve face contacted one another the bluein...

Page 253: ... repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width a again If the valve seat width is ...

Page 254: ... 89 X 42 46 lb at 32 82 mm 12 92 in 3 Measure Svalve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake valve spring 1 7 mm 0 07 in Exhaust valve spring 1 7 mm 0 07 in EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Svalve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00245 INSTALLIN...

Page 255: ...ger pitch a facing up b Smaller pitch Make sure that each valve is installed in its origi nal place Refer to the following embossed marks Right and left intake valve s 5VY Middle intake valve s 5VY Exhaust valve s 5VY 4 Install Svalve cotters 1 Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Valve spring comp...

Page 256: ...t face hammer Hitting the valve tip with excessive force could damage the valve 6 Install Svalve pad 1 Svalve lifter 2 SLubricate the valve lifter and valve pad with molybdenum disulfide oil SThe valve lifter must move smoothly when ro tated with a finger SEach valve lifter and valve pad must be rein stalled in its original position ...

Page 257: ...2 1 1 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 14 Nm 1 4 mSkg 10 ftSlb 22 Nm 2 2 mSkg 16 ftSlb 22 Nm...

Page 258: ...r Idler gear Idler gear shaft Washer Bearing 1 1 1 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 14 Nm 1 4 mSkg 10 ftSlb 22 Nm 2 2 mSkg 16 ftSlb 22 Nm 2 2 mSkg 16 ftSlb ...

Page 259: ...he starter clutch Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O ring 1 3 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure STARTER CLUTCH AND GENERATOR ENG STARTER CLUTCH ...

Page 260: ...3 Drain Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 4 Remove Splug Sgenerator rotor cover 1 SWhile pushing generator rotor remove the generator rotor cover SLoosen each bolt 1 4 of a turn a time in stages and in a crisscross pattern SAfter all of the bolts are fully loosened remove them 5 Remove Sgenerator rotor and starter clutch assembly 1 6 Remove Sidler gear shaft bolt 1 Sidler s...

Page 261: ... REMOVING THE STARTER CLUTCH 1 Remove Sspacer 1 SO ring 2 Swasher 3 2 Remove SStarter clutch drive gear 1 Scollar 2 Swasher 3 3 Remove Sdriven gear 1 Sdampers 2 Sgenerator rotor 3 CHECKING THE DAMPER 1 Check Sdampers 1 Damage wear Replace ...

Page 262: ...ge pitting wear Replace the starter clutch gear 4 Check Sstarter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear counterclockwise A the starter clutch and the starter clutch drive gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clut...

Page 263: ...talled to the generator side SLubricate the engine oil 4 2 Install Sstarter clutch drive gear 1 Scollar 2 Swasher 3 Refer to CHECKING THE STARTER CLUTCH 3 Install Swasher 1 SO ring 2 New Sspacer 3 Lubricate the engine oil to O ring INSTALLING THE GENERATOR 1 Install Sidle gear shaft Sidle gear 1 Swasher Sidle gear shaft bolt 2 LOCTITE 2 Install Sgenerator rotor and starter clutch assembly 1 ...

Page 264: ...bolts SFirst tighten the M8 bolts and then tighten the M6 bolts STighten the generator rotor cover bolts in stages and in a crisscross pattern 4 Fill Sengine oil Refer to CHANGING THE ENGINE OIL in chapter 3 5 Install Sbottom cowling Sleft side cowling Refer to COWLINGS in chapter 3 6 Install Sfuel tank Srider seat Refer to SEATS and FUEL TANK in chap ter 3 ...

Page 265: ...otor cover Gasket Cover 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb CRANKSHAFT POSITION SENSOR...

Page 266: ...crankshaft position sensor lead coupler 5 Remove Scrankshaft position sensor SO ring Spickup rotor cover 1 Loosen each bolt 1 4 of a turn a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Sgasket New Spickup rotor cover 1 SO ring New Scrankshaft position sensor LOCTITE 2 Connect Scrankshaft positio...

Page 267: ...5 45 CRANKSHAFT POSITION SENSOR ENG 5 Install Srider seat Sfuel tank Refer to SEATS and FUEL TANK in chap ter 3 ...

Page 268: ...over Clutch cover gasket Dowel pin Oil filler cap 1 1 1 1 2 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect For installation reverse the removal procedure Refer to COWLINGS in chapter 3 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb CLUTCH ENG CLUTCH CLUTCH COVER ...

Page 269: ...y Remarks 1 2 3 4 5 6 Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing 2 1 1 1 1 2 Remove the parts in the order listed For installation reverse the removal procedure PULL LEVER SHAFT ...

Page 270: ...g Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat 6 1 1 1 1 7 7 1 1 1 1 1 Remove the parts in the order listed 10 Nm 1 0 mSkg 7 2 ftSlb 95 Nm 9 5 mSkg 69 ftSlb CLUTCH ENG CLUTCH ...

Page 271: ...er Job Part Q ty Remarks 13 14 15 16 17 18 Clutch boss nut Washer Clutch boss Thrust plate Clutch housing Bearing 1 1 1 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 95 Nm 9 5 mSkg 69 ftSlb ...

Page 272: ... a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 2 Remove Scompression spring bolts 1 Scompression springs Spressure plate 2 Spull rod 3 3 Remove Sfriction plate 1 4 Remove Sclutch plate 1 1 Sfriction plate 2 5 Straighten the clutch boss nut rib 1 ...

Page 273: ...Remove Sclutch boss nut Swasher Sclutch boss assembly Sthrust plate 8 Remove Swire clip 1 There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 1 and disassemble the built in damper unless there is serious clutch chattering 9 Remove Sclutch plate 2 1 Sfriction plate 3 2 10 Remove Sclutch damper spring 1 Sclutch damper spring seat 2 ...

Page 274: ...on plates as a set Measure the friction plate at four places Friction plate thickness 2 9 X 3 1 mm 0 114 X 0 122 in Limit 2 8 mm 0 110 in EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Sclutch plate Damage Replace the clutch plates as a set 2 Measure Sclutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replac...

Page 275: ...ngth 52 5 mm 2 07 in Limit 49 9 mm 1 96 in EAS00284 CHECKING THE CLUTCH HOUSING 1 Check Sclutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Sbearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check Sclutch boss splines Damage ...

Page 276: ...EVER SHAFT AND PULL ROD 1 Check Spull lever shaft pinion gear teeth 1 Spull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 2 Check Spull rod bearing Damage wear Replace INSTALLING THE CLUTCH 1 Install Sclutch damper spring seat 1 Sclutch damper spring 2 2 Install Sfriction plate 3 1 Sclutch plate 2 2 Lubricate the engine oil ...

Page 277: ...lutch boss assembly 1 Swasher Sclutch boss nut 2 New SInstall the washer on the main axle with the OUT mark facing away from the motorcycle SLock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle SWhile holding the clutch boss assembly 1 with the clutch holding tool 3 tighten the clutch boss nut Universal clutch holder 90890 0408...

Page 278: ...stall Sfriction plate 2 Sclutch plate 1 1 8 Install Sfriction plate 1 1 Install the last friction plate shifting half phase 9 Install Sbearing Spull rod 1 Spressure plate 2 Sclutch springs Sclutch spring bolts 3 Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Install Spull lever In stall the pull lever with the f mark facing to ward upper side ...

Page 279: ...SWhen installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged STighten the clutch cover bolts in stages and in a crisscross pattern 12 Tighten Sclutch cover bolts 1 Sclutch cover bolt 2 LOCTITE Tighten the clutch cover bolts in a stages...

Page 280: ...ssembly Sift arm and shift rod Circlip Washer Shift shaft Collar Shift shaft spring Washer Stopper screw Stopper lever Washer 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CLUTCH Refer to ENGINE Refer to COWLINGS in chapter 3 22 Nm 2 2 mSkg 16 ftSlb SHIFT SHAFT ENG EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER ...

Page 281: ...5 59 SHIFT SHAFT ENG Order Job Part Q ty Remarks 10 11 12 13 Oil seal Bearing Bearing Stopper lever spring 1 1 1 1 For installation reverse the removal procedure 22 Nm 2 2 mSkg 16 ftSlb ...

Page 282: ...er to COWLINGS in chapter 3 2 Remove Sclutch assembly Refer to CLUTCH 3 Remove Sshift arm Sshift rod Refer to ENGINE 4 Remove Scirclip 1 SWasher 2 left side of the engine 5 Remove Sshift shaft 1 Sshift shaft spring 2 Scollar Swasher 6 Remove Sstopper lever spring 1 Sstopper screw 2 Sstopper lever 3 Swasher ...

Page 283: ...ller turns roughly Replace the stopper lever INSTALLING THE SHIFT SHAFT 1 Install Swasher Sstopper lever 1 Sstopper screw 2 LOCTITE Sstopper lever spring 3 2 Install Swasher Scollar Sshift shaft spring 1 Sshift shaft 2 SMesh the stopper lever with the shift drum seg ment assembly SLubricate the oil seal lips with lithium soap base grease SInstall the end of the shift shaft spring onto the shift sh...

Page 284: ...5 62 SHIFT SHAFT ENG 4 Install Sshift rod Sshift arm Refer to ENGINE 5 Install Sclutch assembly Refer to CLUTCH 6 Install Sleft and side cowling Sbottom cowlings Refer to COWLING in chapter 3 ...

Page 285: ...l pan Oil pan gasket Dowel pin Drain pipe Oil strainer 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to EXHAUST PIPE Refer to CLUTCH Refer to OIL COOLER in chapter 6 Disconnect Refer to COWLINGS in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 43...

Page 286: ...n guide Collar Oil water pump assembly drive sprocket Washer Oil water pump assembly drive chain Dowel pin Oil water pump assembly 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 43 Nm 4 3 mSkg 31 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 287: ...driven sprocket Collar Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin 1 1 1 1 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 15 Nm 1 5 mSkg 11 ftSlb OIL PAN AND OIL PUMP ENG EAS00360 ...

Page 288: ...ages and in a crisscross pattern After all of the bolts are fully loosened remove them CHECKING THE SPROCKET AND CHAIN 1 Check Soil water pump assembly drive sprocket 1 Cracks damage wear Replace the de fective part s 2 Check Soil water pump assembly drive chain 1 Damage stiffness Replace the oil water pump assembly drive chain and oil water pump assembly drive sprocket as a set ...

Page 289: ... 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 01 X 0 10 mm 0 0004 X 0 0039 in Limit 0 18 mm 0 0071 in Outer rotor to oil pump housing clearance 0 09 X 0 15 mm 0 0035 X 0 0059 in Limit 0 22 mm 0 0087 in 3 Check Soil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS00365 CHECKING THE RELIEF VALVE 1 Check Srelief valve ...

Page 290: ...iner 1 Damage Replace Contaminants Clean with solvent EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Soil nozzle 1 Damage wear Replace the oil nozzle SO ring 2 Damage wear Replace Soil nozzle passage Obstruction Blow out with compressed air EAS00374 ASSEMBLING THE OIL PUMP 1 Lubricate Sinner rotor Souter rotor Soil pump shaft with the recommende...

Page 291: ... rotor align the pin 1 in the oil pump shaft with the groove a in the inner rotor 2 3 Install Soil water pump driven sprocket 1 LOCTITE 5VY mark of the oil water pump driven gear is installed at oil pump side 4 Check Soil pump operation Refer to CHECKING THE OIL PUMP INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install SO ring New Soil water pump assembly 1 Sdowel pin Sbolts 2 LOCTITE ...

Page 292: ... chain 1 onto the oil water pump assembly drive sprocket 2 After installing the oil water pump assem bly drive chain and drive sprocket make sure the oil water pump turns smoothly 3 Install Soil water pump assembly drive chain guide 1 LOCTITE UP mark of the oil water pump assembly drive chain guide is upward 4 Install Soil delivery pipe 1 LOCTITE 5 Install Srelief valve 1 SO ring New Soil strainer...

Page 293: ... 31 ftSlb WARNING NOTE EAS00380 INSTALLING THE OIL PAN 1 Install Sdowel pins Sgasket New Soil pan 1 Soil level switch 2 Sengine oil drain bolt 3 Always use new copper washers STighten the oil pan bolts in stages and in a crisscross pattern SLubricate the oil level switch O ring with en gine oil ...

Page 294: ...ILTER CASE in chapter 3 Refer to THROTTLE BODIES in chapter 7 Refer to ENGINE Refer to CYLINDER HEAD Refer to STARTER CLUTCH AND GENERATOR Refer to SHIFT SHAFT Refer to CRANKSHAFT POSITION SENSOR Refer to CLUTCH Refer to OIL PAN AND OIL PUMP Refer to STARTING SYSTEM in chapter 8 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 24 Nm 2 4 mSkg 17 ftS...

Page 295: ...chain guide exhaust side Left side cover O ring Lower crankcase Dowel pin Damper 1 1 2 1 1 1 1 3 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 24 Nm 2 4 mSkg 17 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 60_ ...

Page 296: ...X 10 M8 60 mm 2 4 in bolt 11 LOCTITE M8 60 mm 2 4 in bolts 12 16 M6 70 mm 2 8 in bolts 19 21 23 M6 65 mm 2 5 in bolts 17 18 M6 60 mm 2 4 in bolts 22 24 25 M6 50 mm 2 0 in bolts 20 26 M8 50 mm 2 0 in bolts 13 X 15 3 Remove Slower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and c...

Page 297: ... Check Sbearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check Soil seals Damage wear Replace ASSEMBLING THE CRANKCASE 1 Lubricate Scrankshaft journal bearings with the recommended lubricant Recommended lubricant Engine oil 2 Apply Ssealant Yamaha bond No 1215 90890 85505 ACC 1109 05 01 Do not allow any sealant to come into contact with...

Page 298: ...er on bolts 1 X 10 and 22 SSeal bolt 18 STighten the bolts in the tightening sequence cast on the crankcase M9 105 mm 4 1 in bolts 1 X 10 M8 60 mm 2 4 in bolt 11 LOCTITE M8 60 mm 2 4 in bolts 12 16 M6 70 mm 2 8 in bolts 19 21 23 M6 65 mm 2 5 in bolts 17 18 M6 60 mm 2 4 in bolts 22 24 25 M6 50 mm 2 0 in bolts 20 26 M8 50 mm 2 0 in bolts 13 X 15 Crankcase bolt Bolt 1 X 10 1st 20 Nm 2 0 mSkg 14 ftSlb...

Page 299: ...d upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Cylinder Cylinder gasket 4 4 4 8 4 4 4 4 4 4 1 1 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure 20 Nm 2 0 mSkg 14 ftSlb 150_ 8 Nm 0 8 mSkg 5 8 ftSlb CONNECTING RODS AND PISTONS ENG EAS00252 CONNECTING RODS AND PISTONS ...

Page 300: ... connecting rod caps 2 Remove SCylinder SCylinder gasket SCylinder stud bolts 3 Remove Spiston pin clips 1 Spiston pin 2 Spiston 3 Do not use a hammer to drive the piston pin out SFor reference during installation put identifica tion marks on the piston crown SBefore removing the piston pin deburr the pis ton pin clip groove and the piston pin bore area If both areas are debarred and the piston pi...

Page 301: ...r bearing so that it can be reinstalled in its original place EAS00261 CHECKING THE CYLINDER AND PISTON 1 Check Spiston wall Scylinder wall Vertical scratches Replace the cylinder and the piston and piston rings as a set 2 Measure Spiston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge Measure cylinder bore C by taking side to side and front to back measurements of the...

Page 302: ...n size P 76 975 X 76 990 mm 3 0305 X 3 0311 in d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 010 X 0 035 mm 0 0004 X 0 0014 in Limit 0 120 mm 0 0047 in f If out of specification replace the cylinder and ...

Page 303: ...Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 15 X 0 25 mm 0 0059 X 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring 0 30 X 0 45 mm 0 0118 X 0 0177 in Limit 0 80 mm 0 0315 in Oil ring 0 10 X 0 40 mm 0 0039 X 0 0158 in CHECKING THE PISTON PINS The...

Page 304: ...6710 in 4 Calculate Spiston pin to piston clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston clearance Piston pin bore size Piston pin outside diameter Piston pin to piston clearance 0 002 X 0 022 mm 0 0001 X 0 0009 in Limit 0 072 mm 0 0028 in CHECKING THE BIG END BEARINGS 1 Measure Scrankshaft pin to big end bearing clear ance Out of specification Repla...

Page 305: ...ing rod and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves SDo not move the connecting rod or crankshaft until the clearance measurement has been completed SLubricate the bolt threads with m...

Page 306: ...nce using a single unit of the connecting rod i Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touching the surface SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out of alignment j Loosen the connecting ...

Page 307: ...Side machined face a SWhen the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bolt and big end bear ing and restart from step e In this case make sure to replace the connecting rod bolt SDo not use a torque wrench to tighten...

Page 308: ...rmine the replacement big end bearing sizes S P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 re spectively then the bearing size for P1 is P1 connecting rod P1 crankshaft 5 2 3 brown BIG END BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green INSTALLING THE CONNECTING ROD AND PISTON The following p...

Page 309: ...e arrow mark b on the piston is pointing up Refer to the illustra tion SReinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Spiston Spiston rings Scylinder with the recommended lubricant Recommended lubricant Engine oil 4 Offset Spiston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5 Lubric...

Page 310: ...notches b in the connecting rods and connecting rod caps SBe sure to reinstall each big end bearing in its original place SMake sure that the characters c on both the connecting rod and connecting rod cap are aligned 9 Tighten Install by carrying out the following procedures in order to assemble in the most suitable condi tion Sconnecting rod bolts SFirst tighten the bolts to 15 Nm 1 5 mSkg 11 ftS...

Page 311: ... SSide machined face a SThrusting faces 4 places at front and rear b To install the big end bearing care should be taken not to install it at an angle and the position should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition 10 Install Spiston ass...

Page 312: ...ing rod and connecting rod cap are aligned 12 Tighten Sconnecting rod bolts Tighten the connecting rod bolts using the plastic region tightening angle method a Clean the connecting rod bolts b Tighten the connecting rod bolts c Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 d Tighten the bolt further to reach the specified angle 150_ e After the installation check that the...

Page 313: ...lace the bolt with a new one and per form the procedure again SIf they are not flush with each other remove the connecting rod bolt and big end bear ing and restart from step 9 In this case make sure to replace the con necting rod bolt SDo not use a torque wrench to tighten the bolt to the specified angle STighten the bolt until it is at the specified angles ...

Page 314: ...Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear Pin Pickup rotor 1 5 5 1 1 1 1 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS For installation reverse the removal procedure 60 Nm 6 0 mSkg 43 ftSlb CRANKSHAFT ENG EAS00381 CRANKSHAFT ...

Page 315: ...racks damage wear Replace the de fective part s CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure Scrankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 014 X 0 037 mm 0 0006 X 0 0015 in Limit 0 10 mm 0 0039 in Do not interchange the crankshaft journal bearings To obtain...

Page 316: ...ower bearings 1 into the lower crankcase and assemble the crankcase halves SAlign the projections a of the crankshaft jour nal lower bearings with the notches b in the lower crankcase SDo not move the crankshaft until the clearance measurement has been completed f Tighten the bolts to specification in the tight ening sequence cast on the crankcase Crankcase bolt Bolt 1 X 10 1st 20 Nm 2 0 mSkg 14 f...

Page 317: ...elect Scrankshaft journal bearings J1 X J5 SThe numbers A stamped into the crankshaft web and the numbers 1 stamped into the low er crankcase are used to determine the re placement crankshaft journal bearing sizes S J1 X J5 refer to the bearings shown in the crankshaft illustration SIf J1 X J5 are the same use the same size for all of the bearings SIf the size is the same for all J1 to J5 one digi...

Page 318: ...l upper bearings with the recommended lubricant Recommended lubricant Engine oil SAlign the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase SBe sure to install each crankshaft journal up per bearing in its original place 3 Install Scrankshaft 4 Install Scrankcase lower Refer to CRANKCASE 5 Install Spin Spickup rotor 1 Sdrive sprocket 2 ...

Page 319: ...sher Shift drum retainer Spring Shift fork guide bar Shift fork L Shift fork R Shift drum assembly Shift fork C 1 1 1 1 1 2 2 2 1 1 1 1 Remove the part in the order listed Separate Refer to CRANKCASE 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb TRANSMISSION ENG EAS00419 TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS ...

Page 320: ...arks 13 14 15 16 17 Main axle retainer Main axle assembly Oil pipe O ring Oil baffle plate 1 1 1 2 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb ...

Page 321: ...inion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 TRANSMISSION ENG ...

Page 322: ...5 100 Order Job Part Q ty Remarks Bearing housing Bearing 1 1 For installation reverse the removal procedure 14 15 TRANSMISSION ENG ...

Page 323: ... 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TRANSMISSION ENG ...

Page 324: ...SION ENG Order Job Part Q ty Remarks 6th wheel gear Circlip Washer Collar 2nd wheel gear Collar Oil seal Bearing Drive axle 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 15 16 17 18 19 20 21 22 23 ...

Page 325: ...er size as shown in the illustration into the main axle assembly bearing housing b Tighten the bolts until they contact the crank case surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Soil pipe 1 Sbearing 2 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Sshift fork cam follower 1 S...

Page 326: ...nd shift fork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Sshift drum grooves 1 Damage scratches wear Replace the shift drum assembly Sshift drum segment 2 Damage wear Replace the shift drum as sembly Sshift drum bearing 3 Damage pitting Replace the shift drum assembly EAS00425 CHECKING THE TRANSMISSION 1 Measure Smain axle runout with a centering device and dial gauge 1 O...

Page 327: ... TRANSMISSION 1 Install Sbearing 1 Make the seal side of bearing face to the outside and install it close to the right end face of the crankcase Soil pipe 2 2 Install Smain axle assembly 1 Sbearing housing 2 LOCTITE Sshift fork C Sshift drum assembly Sshift fork guide bar Sshift fork guide bar retainer LOCTITE SThe embossed marks on the shift forks should face towards the right side of the engine ...

Page 328: ...guide bar retainer 4 LOCTITE SInstall shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle SMake sure that the drive axle bearing circlip a is inserted into the grooves in the upper crank case 4 Check Stransmission Rough movement Repair Oil each gear shaft and bearing thoroughly ...

Page 329: ...adiator fan motor Radiator inlet hose 1 1 1 2 1 Remove the parts in the order listed Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Refer to COWLINGS in chapter 3 Refer to SEATS in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR ...

Page 330: ...or inlet pipe Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe O ring 1 1 1 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb ...

Page 331: ...essure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 108 X 137 kPa 1 08 X 1 37 kg cm2 1 0 X 1 3 bar 15 6 X 19 9 psi a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 b Apply the specified pressure for ten seconds and make sure ...

Page 332: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check Scooling system Leaks Repair or replace any faulty part 3 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 333: ...lt Washer Oil cooler O ring Water pump outlet pipe O ring Water jacket joint inlet hose O ring 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 63 Nm 6 3 mSkg 46 ftSlb OIL COOLER COOL EAS00457 OIL COOLER ...

Page 334: ...L COOLER COOL Order Job Part Q ty Remarks 10 11 12 Water jacket joint Stay O ring 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 63 Nm 6 3 mSkg 46 ftSlb ...

Page 335: ...l cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil SMake sure that the O ring is positioned proper ly SAlign the projection a on the oil cooler with the slot b in the crankcase 3 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 Scrankcase with the specified amount of the recom mended engine oil Refer...

Page 336: ...stat assembly breather hose Thermostat assembly Thermostat assembly inlet hose Band 1 1 1 1 2 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter3 For installation reverse the removal procedure THERMOSTAT COOL EAS00460 THERMOSTAT ...

Page 337: ...ty Remarks Disassembling the thermostat housing Thermostat housing cover Thermostat Thermostat housing O ring 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 10 Nm 1 0 mSkg 7 2 ftSlb ...

Page 338: ...r c Place a thermometer in the water d While stirring the water observe the thermo stat and thermometer s indicated tempera ture 1 Thermometer 2 Water 3 Thermostat 4 Container A Fully closed B Fully open If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Sthermostat housing cover 1 Sthermostat housing 2 Cracks damage...

Page 339: ...hermostat with its breather hole a facing up EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1 Fill Scooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check Scooling system Leaks Repair or replace any faulty part 3 Measure Sradiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 340: ...with the impeller 1 1 2 1 Remove the parts in the order listed SThe water pump and oil pump are com bined into one unit oil water pump as sembly SIt is not necessary to remove the impeller shaft unless the coolant level is extreme ly low or coolant leaks from the oil pan Refer to OIL PAN AND OIL PUMP in chapter 5 12 Nm 1 2 mSkg 8 7 ftSlb NOTE EAS00468 WATER PUMP IMPELLER SHAFT ...

Page 341: ...6 13 WATER PUMP COOL Order Job Part Q ty Remarks 5 6 7 8 Water pump seal Oil seal Bearing O ring 1 1 1 1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 8 7 ftSlb ...

Page 342: ... the water pump housing 3 Water pump housing 3 Remove Srubber damper holder 1 Srubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00473 CHECKING THE WATER PUMP 1 Check Swater pump housing cover 1 Swater pump housing 2 Simpeller 3 Srubber damper 4 Srubber damper holder 5 Swater pump seals Soil seal Cracks damage wear Replace 2 Check Sbearing Rou...

Page 343: ...e the water pump seal surface with oil or grease SInstall the water pump seal with the special tools SBefore installing the water pump seal apply Yamaha bond No 1215 or Quick Gasket 2 to the water pump housing 3 Mechanical seal installer 4 90890 04078 YM 33221 Middle driven shaft bearing driver 5 90890 04058 YM 04058 Yamaha bond 1215 90890 85505 Quick gasket ACC 11001 05 01 A Push down 3 Install S...

Page 344: ...ION 4 Measure Simpeller shaft tilt Out of specification Repeat steps 3 and 4 Make sure the rubber damper and rubber damper holder are flush with the impeller Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller ...

Page 345: ...re sensor 14 Spark plug 15 Cylinder identification sensor 16 Pressure regulator 17 Battery 18 ECU 1 Ignition coil 2 Air filter case 3 Intake temperature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump 7 Fuel return hose 8 Intake air presure sen sor 9 Throttle position sen sor 10 Fuel injector 11 Catalytic converter 12 Crankshaft position sensor FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ...

Page 346: ...7 2 FUEL INJECTION SYSTEM FI 7 WIRING DIAGRAM ...

Page 347: ...nition coil 4 19 Spark plug 20 Injector 1 21 Injector 2 22 Injector 3 23 Injector 4 25 Sub throttle position sensor 26 EXUP servo motor 27 Speed sensor 28 Coolant temperature sensor 29 Intake air temperature sensor 31 Crankshaft position sensor 32 Throttle position sensor 33 Intake air pressure sensor 34 Atmospheric pressure sensor 35 Cylinder identification sensor 36 Lean angle cut off switch 43 ...

Page 348: ...y illumi nating an engine trouble warning light SAfter the engine has been stopped the fault code number appears from the lowest value in order of precedence on the LCD meter Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted EAS00900 Engine trouble warning light indication and FI system operating condition Warning light indication ECU s operation F...

Page 349: ...tor lock A lock of the EXUP servo motor is detected S Perform the preventive control against motor locking Perform the lock release operation twice every 100 seconds Able Able 19 Sidestand switch open circuit in wire to ECU Open circuit in the input line of ECU No 15 terminal is detected when the start switch is pressed No start Unable Unable 20 Intake air pressure Atmospheric pressure Defective v...

Page 350: ...d the code number might not appear on the meter Unable Unable Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON When the start switch is turned ON while an error is detected with the fault code of No 11 12 19 30 41 or 50 Engine trouble warning light flashes when the start switch is turned ON Unable Unable Communication error with the ...

Page 351: ...malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer to the Diagnostic mode table Diagnostic code No 62 Repairs completed The engine trouble warning light does not come on Check the operation of following sensors and ac tuators in the diagnostic mode Refer to Diagnos tic mode table in chapter 7 Malfunction of en gin...

Page 352: ...t the clock and tripmeter displays S dIAG appears on the LCD meter 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 se conds or more to execute the selection 6 Select the diagnostic code number that ap plies to the item that was verified with the fault code number by pressing the...

Page 353: ...rs on the trip LCD SActuator operation Set the engine stop switch to ON to operate the actuator If the engine stop switch is set to ON set it to OFF and then set it to ON again 8 Turn the main switch to OFF to cancel the the diagnostic mode To perform a reliable diagnosis make sure to turn OFF the power supply before every check and then start right from the beginning ...

Page 354: ...open or short circuit detected S Open or short circuit in wiring sub lead S Detective EXUP servo motor potention circuit 53 18 EXUP servo motor is stuck S Open or short circuit in wiring sub lead S Stuck EXUP servo motor mechanism S Stuck EXUP servo motor motor 53 19 Open circuit in the input line of ECU No 15 terminal is detected when the start switch is pressed S Open circuit in wiring harness E...

Page 355: ...onitor the battery voltage an open circuit in the monitor line to the ECU S Open circuit in wiring harness S Malfunction in ECU 09 44 An error is detected while reading or writing on EEPROM S Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memory 60 46 Power supply to the FI system is not normal S Malfunction in CHARGING SYSTEM 47 Sub throttle servo ...

Page 356: ...mperature in the air cleaner case Compare it to the value displayed on the meter 06 Coolant temperature Displays the coolant temperature Check the temperature of the coolant Compare it to the value displayed on the meter 07 Vehicle speed pulse Displays the accumulation of the vehicle pulses that are generated when the tire is spun 0 X 999 resets to 0 after 999 OK if the numbers appear on the meter...

Page 357: ...mes every second and illuminates the engine trouble warning light If 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 the engine stop switch has been turned from OFF to ON it actuates the injector 4 five times every second and illuminates the engine trouble warning light If the...

Page 358: ...it back on Turn on the engine trouble warn ing light while servo motor is op erated Operating angle is dis played on the LCD meter 60 EEPROM fault code display S Transmits the abnormal portion of the data in the E2PROM that has been detected as a self diagnostic fault code 44 S If multiple malfunctions have been detected different codes are displayed at 2 second intervals and this process is repea...

Page 359: ...dentification sensor Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of sensor Check the installed area for looseness or pinching Reinstated by starting the 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If ...

Page 360: ...Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Crankshaft position sensor coupler Main wiring harness ECU coupler engine 3 Open or short circuit in wiring harness Repair or replace if there is an open or short circuit between the main wiring harnesses Between sensor coupler and ECU cou...

Page 361: ...pler If there is a malfunction repair it and connect it securely Intake air pressure sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Black Blue Black Blue Pink White Pink White Blue B...

Page 362: ...essure sensor malfunction at intermediate electrical potential Repair or replace the sensor hose Inspect and repair the connection Reinstated by starting the engine and operating it at 2 Connected condition of connector Intake air pressure sensor coupler Main wiring harness ECU coupler Check the coupler for any pins that may have pulled out Check the looking condition of the coupler If there is a ...

Page 363: ...ack Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and replace the throttle position sensor Black Blue Yellow Open circuit item Output voltage Ground wire open 5 V circuit Output wire open 0V circuit Power supply wire 0V open circuit 5 Defective throttle position sensor Execute the diagnostic mode Code No 01 Rep...

Page 364: ...condition of the coupler If there is a malfunction repair it and connect it securely EXUP servo motor coupler Main wireharness ECU coupler Reinstated by turning the main switch ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between motor coupler and ECU coupler Blue Blue White Red White Red Black Blue Black Blue 3 Defective EXUP servo motor potent...

Page 365: ...curely EXUP servo motor coupler Main wire harness ECU coupler Reinstated by turning the main switch ON It takes 120 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between motor coupler and ECU coupler Black Green Black Green Black Red Black Red seconds at the maximum before the original state returns 3 Defective EXUP servo motor Execute the diagnosti...

Page 366: ...f there is an open or short circuit Between sidestand switch coupler and ECU coupler Blue Black Black transmission is in neutral it is reinstated by reconnecting the wiring 3 The malfunction of the sidestand switch Replace if defective Refer to CHECKING THE SWITCHES in chapter 8 Fault code No 20 Symptom Defective values are detected due to the internal malfunction of the intake air pressure sensor...

Page 367: ... out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Coolant temperature sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON 2 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 B...

Page 368: ...nnector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Intake temperature sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON 2 Open or short circuit in wiring harness and or sub lead Repair or replace if there is an open or ...

Page 369: ...the locking condition of the coupler If there is a malfunction repair it and connect it securely Atmospheric pressure sensor coupler Main wiring harness ECU coupler Reinstated by turning the main switch ON 2 Open or short circuit in wiring harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Blue Blue Black Blue Black Blue Pink Pink 3 Defective atmo...

Page 370: ...nspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Lean angle cut off switch coupler Main wiring harness ECU coupler ON however the engine cannot be restarted unless the main switch is 4 Defective lean angle cut off switch Execute the diagnostic mode Code No 08 Replace if defective 1 Remove...

Page 371: ...dition of the coupler If there is a malfunction repair it and connect it securely Ignition coil primary side coupler Gray Red Main wiring harness ECU coupler Reinstated by starting the en gine and oper ating it at idle 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between ignition coil coupler 2 and ECU coupler main harness Gray Red Gray Red Red Black ...

Page 372: ...l test the primary and secondary coils for continuity Execute the diagnostic mode Code No 33 Replace if defective Refer to IGNITION SYSTEM in chapter 8 Fault code No 41 Symptom Open or short circuit detected in the lean angle cut off switch Used diagnostic code No 08 lean angle cut off switch Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method ...

Page 373: ...20 to 30 km h A3 Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective 1 Measure the speed sensor output voltage 2 Connect the pocket tester DC 20 V to the speed sensor coupler terminal as shown 3 Measure the speed sensor output voltage 4 Is the speed sensor OK A4 Gear for detecting vehicle speed has broken Replace if defective Refer to TRANSMISSION in chapter 5 Order ...

Page 374: ...nnect it securely Starting circuit cut off relay coupler fuel injection system relay ECU coupler Reinstated by starting the engine and operating it at idle 2 Malfunction in ECU Fuel injection system relay is on 3 Open or short circuit in the wiring harness Repair or replace if there is an open or short circuit Between battery terminal and ECU coupler Red white Red white Red Blue Yellow Main switch...

Page 375: ... FI system relay is not normal Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely ECU coupler Reinstated by starting the engi...

Page 376: ...on Reinstated by turning the main switch ON 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Throttle position sensor coupler Main wiring harness ECU coupler Sub wire harness coupler 3 Open or short circuit in wiring harness and or sub lead Repair or re...

Page 377: ...air or replace if there is an open or short circuit Between motor coupler and ECU coupler Yellow Red Yellow Red Yellow White Yellow White seconds at the maximum before the original state returns 3 Defective sub throttle servo motor Execute the diagnostic mode Code No 56 Replace if defective 1 Disconnect the sub throttle cables from the Sub throttle servomotor pulley 2 Disconnect the sub throttle s...

Page 378: ...nt method 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Reinstated by turning the main switch ON 2 Open or short circuit in wiring harness and or sub lead...

Page 379: ...t hose Thermo wax outlet hose Idle adjust screw wire Throttle body joint clamp Throttle bodies Throttle cables 2 1 1 1 1 4 1 2 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Disconnect Disconnect Loosen If it loosens too much the nut will sepa rate Disconnect NOTE THROTTLE BODIES FI THROTTLE BODIES ...

Page 380: ...Heat protector Fuel hose 4 1 1 To install the throttle body joint make sure to install it to the cylinder with the same figures corresponding to the fig ures stated on the throttle body joint For installation reverse the removal procedure NOTE THROTTLE BODIES FI ...

Page 381: ...r coupler Cylinder 1 injector coupler Cylinder 2 injector coupler Cylinder 3 injector coupler Cylinder 4 injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Spring Thermo wax assembly 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 Remove the parts in the order listed Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect Disconnect THR...

Page 382: ...Remarks 16 17 18 19 20 21 22 23 Idle adjust screw wire Cotter pin Washer Link Sub throttle servo motor assembly Throttle position sensor Fuel pressure regulator Throttle body assembly 1 2 2 1 1 1 1 1 For installation reverse the removal procedure ...

Page 383: ...fuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with com pressed air EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Sthrottle bodies Refer to THROTTLE BODIES 2 Check Sthrottle body jo...

Page 384: ...onto the negative pressure hose from the pressure regulator d Connect the pressure gauge 3 and adapter 4 onto the fuel injection pipe Vacuum pressure pump gauge set 90890 06756 YB 35956 Pressure gauge 90890 03153 YU 03153 Adapter 90890 03176 YM 03176 e Install the fuel tank Refer to FUEL TANK in chapter 3 f Start the engine g Measure the fuel pressure Fuel pressure 294 kPa 2 94 kg cm2 42 6 psi h U...

Page 385: ... throttle position sensor cou pler b Remove the throttle position sensor from the throttle body c Connect the pocket tester Ω 1k to the throttle position sensor Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 d Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor Maximum throttle position sensor resista...

Page 386: ...read ings from closed to wide open throttle may dif fer slightly from those specified Throttle position sensor resistance 0 X 6 kΩ at 20_C 68_F yellow black 2 Adjust Sthrottle position sensor angle a Connect the throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the throttle position sensor Digital circuit tester 90890 03174 c Measure the throttle position...

Page 387: ...b throttle position sensor resistance 4 X 6 kΩ at 20_C 68_F blue black blue e Connect the pocket tester Ω 1k to the sub throttle position sensor Positive tester probe green yellow terminal 3 Negative tester probe black blue terminal 2 f While slowly opening the sub throttle worm nut check that the sub throttle position sen sor resistance is within the specified range The resistance does not change...

Page 388: ... sections of the throttle bodies 3 and 4 measure the dimension of a sections of 1 and 2 d If the dimension of a sections of the throttle bodies 1 and 2 is different from the dimen sion of a sections of the throttle bodies 3 and 4 adjust it to the same dimension as the measurement value adjusted for the throttle bodies 3 and 4 using the tuning screw 3 located between the throttle bodies 2 and 3 3 A...

Page 389: ...ax 1 Damege Replace the thermo wax 2 Adjust Sthermo wax the end face distance a a Before adjusting the distance push the rod b in order to be fitted in several times by hand b Measure the outside air temperature and adjust the distance a by turning the adjust ing screw 2 Refer to the thermo wax toler ance table based on the measured outside air temperature for correct adjustment SSetup tolerance o...

Page 390: ...ned exhaust gases is approximately 600 to 700_C 1112 to 1292_F EAS0097 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the motorcycle is being driven However if the coolant tempera ture is below the specified...

Page 391: ...7 47 AIR INDUCTION SYSTEM FI A To cylinder 1 and 2 B To cylinder 3 and 4 1 Air cut off valve 2 Plate 3 Reed valve assembly 4 Reed valve cap 5 To air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 392: ...damage Replace Spipes Cracks damage Replace 2 Check S reed valve 1 S reed valve stopper Sreed valve seat Cracks damage Replace the reed valve 3 Measure S reed valve bending limit a Out of specification Replace the reed valve Reed valve bending limit 0 4 mm 0 016 in 1 Surface plate 4 Check Sair cut off valve Cracks damage Replace ...

Page 393: ... from the wire harness b Connect the pocket tester Ω 1 to the Air induction system solenoid terminal as shown Tester positive probe orange 1 Tester negative probe green 2 c Measure the Air induction system solenoid resistance Air induction system solenoid resistance 18 X 22 Ω at 20_C 68_F d Out of specification Replace ...

Page 394: ...l switch 10 Radiator fan motor 11 Horn 12 Ignition coil 1 Main switch 2 Front brake light switch 3 Starter relay 4 Battery 5 Fuse box 6 Rear brake light switch 7 Neutral switch 8 Sidestand switch EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...

Page 395: ... Throttle position sensor 13 Sub throttle position sensor 1 Coolant temperature sensor 2 Intake air temperature sensor 3 Intake air pressure sensor 4 Fuel pump 5 ECU 6 Lean angle cut off switch 7 Starting circuit cut off relay 8 Headlight relay dimmer ELECTRICAL COMPONENTS ELEC ...

Page 396: ...to 0 and to the Ω 1 range SWhen checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a...

Page 397: ...itch 8 Front brake light switch 9 Start switch 10 Oil level switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 398: ... and usually use a bulb holder that must be detached before removing the bulb The ma jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise SBulbs C are used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise CHECKING THE CONDITION OF THE BULBS The following procedure applies...

Page 399: ...quer thinner 2 Check Sbulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 YU 3112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 and check the continuity b Connect the positive tester probe to terminal 1 and the negative tester probe t...

Page 400: ...lies to all of the LEDs 1 Check SLED for proper operation Improper operation Replace a Disconnect the meter assembly coupler me ter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal As for connecting with which coupler terminal refer to CABLE ROUTING in chapter 2 SA wire that is used as a jumper lead must have at least the same capacity of t...

Page 401: ...8 8 IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 402: ...relay 11 Neutral switch 12 Sidestand switch 14 E C U 15 Ignition coil 1 16 Ignition coil 2 17 Ignition coil 3 18 Ignition coil 4 19 Spark plug 31 Crankshaft position sensor 35 Cylinder identification sensor 36 Lean angle cut off switch 53 Engine stop switch 59 Clutch switch 73 Fuse ignition ...

Page 403: ... spark plug IGNITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 ignition ...

Page 404: ...system is OK 5 Ignition coil resistance The following procedure applies to all of the ignition coils SDisconnect the ignition coil leads from the wire harness SConnect the pocket tester Ω 1 to the ignition coil as shown EAS00747 Positive tester probe ignition coil terminal Negative tester probe ignition coil terminal SConnect the pocket tester Ω 1k to the ignition coil as shown SMeasure the primar...

Page 405: ...ity Refer to CHECKING THE SWITCHES SIs the main switch OK YES NO Replace the main switch EAS00748 EAS00750 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES NO Replace the right handlebar switch EAS00751 9 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK ...

Page 406: ...2 1 Positive tester probe blue black Negative tester probe blue yellow No continuity 3 1 YES NO Replace the starting circuit cut off relay When you switch the positive and negative tester probes the readings in the above chart will be reversed SAre the tester readings correct NOTE 13 Lean angle cut off switch SCheck the lean angle cut off switch Refer to FUEL INJECTION SYSTEM in chapter 7 SIs the ...

Page 407: ...y 8 Starter relay 9 Starter motor 10 Starting circuit cut off relay 11 Neutral switch 12 Sidestand switch 53 Engine stop switch 54 Start switch 73 Fuse ignition ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 408: ... 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 cur rent cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN ...

Page 409: ...ttery OK SClean the battery terminals SRecharge or re place the battery EAS00739 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 st...

Page 410: ...ket tester Ω 1 and battery 12 V to the starter relay coupler as shown YES NO Replace the starter relay Positive battery terminal blue white Negative battery terminal red white Positive tester probe red Negative tester probe black 1 2 3 4 SDoes the starter relay have continuity be tween red and black EAS00749 6 Main switch SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the...

Page 411: ...he start switch for continuity Refer to CHECKING THE SWITCHES SIs the start switch OK YES NO Replace the right handlebar switch EAS00764 10 Clutch switch SCheck the clutch switch for continuity Refer to CHECKING THE SWITCHES SIs the clutch switch OK YES NO Replace the clutch switch EAS00763 EAS00752 9 Sidestand switch SCheck the sidestand switch for continuity Refer to CHECKING THE SWITCHES SIs th...

Page 412: ...mbly Starter motor lead Starter motor 1 1 Remove the parts in the order listed Refer to SEAT in chapter 3 Refer to FUEL TANK in chapter 3 Refer to THROTTLE BODIES in chapter 7 For installation reverse the removal procedure 10 Nm 1 0 mSkg 7 2 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb EAS00767 STARTER MOTOR ...

Page 413: ...asher Washer Starter motor yoke Armature assembly O ring Starter motor lead Brush holder Rear cover 1 1 1 1 1 1 2 2 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 5 Nm 0 5 mSkg 3 6 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb 5 Nm 0 5 mSkg 3 6 ftSlb EAS00768 ...

Page 414: ... been grounded to fit the commuta tor Mica undercut 1 5 mm 0 06 in The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 03112 YU 3112 Armature coil Commutator res...

Page 415: ... Sbrush spring force Out of specification Replace the brush springs as a set Brush spring force 5 28 X 7 92 N 538 X 808 gf 18 99 X 28 48 oz 7 Check Sgear teeth Damage wear Replace the gear EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install Sbrush seat 1 Align the slot a on the brush seat with the tab b in the starter motor rear cover 2 Install Sarmature 1 ...

Page 416: ...R ELEC 5 Nm 0 5 mSkg 3 6 ftSlb NOTE 3 Install Sstarter motor yoke 1 SO rings 2 New Sstarter motor rear cover 3 Sbolts Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers ...

Page 417: ...8 24 2 A C magneto 3 Rectifier regulator 4 Fuse main 6 Battery CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 418: ...he battery is fully charged NOTE Minimum open circuit voltage 12 8 V or more at 20_C 68_F SIs the battery OK CHARGING SYSTEM ELEC NOTE YES NO 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK Replace the fuse 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00774 TROUBLESHO...

Page 419: ...ck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly con nected and without defects Properly connect or repair the charging system s wiring EAS00779 Replace the rectifi er regulator 4 Stator coil lead SDisconnect stator coil lead coupler SConnect the pocket tester Ω 1 to the sta tor coil lead coupler as shown Positive tester pro...

Page 420: ...8 27 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 421: ...9 Meter light 57 Dimmer switch 62 Front turn signal position light left 63 Front turn signal position light right 66 Headlight 67 Auxiliary light 68 License plate light 69 Rear brake light switch 70 Tail brake light 71 Headlight relay on off 72 Headlight relay dimmer 74 Fuse signal 75 Fuse headlight ...

Page 422: ...main turn and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main turn and headlight fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00781 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight licence light or meter light Check ...

Page 423: ...to CIRCUIT DIAGRAM SIs the lighting system s wiring properly con nected and without defects Properly connect or repair the lighting system s wiring Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM SDoes the headlight relay dimmer have continuity between black green and black yellow Positive tester probe black green Negative tester probe black yel...

Page 424: ...hen the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Low beam Headlight Positive tester probe black Negative tester probe black green 1 2 Meter assembly coupler wire harness side STurn the main switch to ON SStart the engine SSet the dimmer switch to or SMeasure the voltage DC 12 V of black green or black yellow on the headlight coupler wire harness ...

Page 425: ...e paired Positive tester probe blue red Negative tester probe black 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of blue red on the license plate light coupler wire harness side SIs the voltage within specification 1 This circuit is OK EAS00790 3 The tail brake light fails to come on YES NO 1 Voltage SConnect the pocket tester DC 20 V to the tail brake light coupler wire harness si...

Page 426: ...ion light fails to come on YES NO 1 Turn signal position light and socket SCheck the turn signal position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SAre the turn signal position light bulb and socket OK Replace the turn sig nal position light bulb socket or both YES NO 2 Voltage SConnect the pocket tester DC 20 V to the turn signal position light coupler wir...

Page 427: ...8 34 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 428: ...light 41 Tachometer 42 Shift timing indicator light 43 Multi function meter 45 Coolant temperature indicator light 47 Turn signal indicator light left 48 Turn signal indicator light light 55 Turn signal relay 58 Horn switch 60 Turn signal switch 61 Horn 62 Front turn signal position light left 63 Front turn signal position light right 64 Rear turn signal light left 65 Rear turn signal light right ...

Page 429: ... to CHECK ING THE LIGHTING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Backup main ignition signal and park fuses SCheck the backup main ignition signal and park fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the backup main ignition signal and park fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 ...

Page 430: ...main switch to ON SPull in the brake lever or push down on the brake pedal SMeasure the voltage DC 12 V of yellow on the tail brake light coupler wire harness side SIs the voltage within specification 1 YES NO 2 Voltage SConnect the pocket tester DC 20 V to the horn connector at the horn terminal as shown The wiring circuit from the main switch to the horn connec tor is faulty and must be repaired...

Page 431: ...SConnect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown Positive tester probe brown Negative tester probe ground 1 STurn the main switch to ON SMeasure the voltage DC 12 V on brown at the turn signal relay coupler wire harness side SIs the voltage within specification 1 YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty ...

Page 432: ...al indicator light OK EAS00801 4 The neutral indicator light fails to come on YES NO Replace the meter assembly YES NO 2 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK Replace the neutral switch 3 Starting circuit cut off relay diode SDisconnect the starting circuit cut off relay coupler from the wire harness SConnect the pocket tes...

Page 433: ... LEDs SCheck the oil level warning light for continu ity When the main switch is turn to ON the oil level warning light is come on SAre the oil level warning light OK Replace the meter assembly EAS00802 5 The oil level warning light fails to come on YES NO 2 Oil level switch SDrain the engine oil and remove the oil level switch from the oil pan SConnect the pocket tester Ω 100 to the oil level swi...

Page 434: ...EAS00803 6 The fuel level warning light fails to come on 1 Fuel sender SDrain the fuel from the fuel tank and remove the fuel pump from the fuel tank SDisconnect the fuel sender coupler from the wire harness SConnect the pocket tester Ω 10 to the fuel sender terminals as shown Positive tester probe green white Negative tester probe black 1 2 Fuel sender resistance Full position of the float 20 X 2...

Page 435: ...i function meter bulb socket SCheck the multi function meter bulb socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS SIs the multi function meter bulb socket OK YES EAS00806 7 The speedometer fails to come on 2 Speed sensor SConnect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Replace the speed sensor NO YES Positive tester probe white yellow Neg...

Page 436: ...8 43 COOLING SYSTEM ELEC EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 437: ...in 6 Battery 14 E C U 28 Coolant temperature sensor 73 Fuse ignition 76 Radiator fan motor relay 77 Fuse radiator fan motor left 78 Fuse radiator fan motor right 79 Radiator fan motor 2 80 Radiator fan motor 1 COOLING SYSTEM ELEC ...

Page 438: ...e main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main ignition and radiator fan motor fuses OK Replace the fuse s EAS00808 TROUBLESHOOTING SThe radiator fan motor fails to turn SThe coolant temperature indicator light fails to light when the engine is warm Check 1 main ignition and radiator fan motor fuses 2 battery 3 main switch 4 radi...

Page 439: ...r relay SDisconnect the radiator fan motor relay form the wire harness SConnect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown SCheck the radiator fan motor for continuity Replace the radiator fan motor relay NO YES Battery positive terminal red white Battery negative terminal green yellow 1 2 SDoes the radiator fan motor relay have conti nuity between red and ...

Page 440: ... Coolant temperature sensor resistance 0_C 32_F 5 21 X 6 37 kΩ 80_C 176_F 0 29 X 0 35 kΩ WARNING SHandle the coolant temperature sensor with special care SNever subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 6 Coolant temperature sensor Replace the coolant temperature sensor NO YES Coolant temperature sensor 20 Nm 2 0 mSkg 14 ftSlb T...

Page 441: ... 48 1 Main switch 4 Fuse main 6 Battery 7 Fuse fuel injection 10 Starting circuit cut off relay 13 Fuel pump 14 E C U 53 Engine stop switch FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 442: ... Fuse main 3 Main switch 4 Fuse ignition 5 Engine stop switch 6 ECU 7 Fuse fuel injection 8 Starting circuit cut off relay fuel injection system relay 9 Fuel pump EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump ...

Page 443: ...ce the right handlebar switch SIs the engine stop switch OK NOTE YES NO 1 Main ignition and fuel injection system fuses SCheck the main ignition and fuel system fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 Replace the fuse s SAre the main ignition and fuel injection sys tem fuses OK EAS00816 TROUBLESHOOTING If the fuel pump fails to operate Check 1 main ignition and fuel injectio...

Page 444: ...e starting circuit cut off relay have continuity between red and red blue YES NO 6 Fuel pump resistance SDisconnect the fuel pump coupler from the wire harness SConnect the pocket tester Ω 1 to the fuel pump coupler as shown Properly connect or repair the fuel sys tem s wiring 1 2 Positive tester probe red blue Negative tester probe black EAS00817 YES NO Fuel pump resistance 0 2 X 3 0 Ω at 20_C 68...

Page 445: ...gasoline wipe it up immediately with dry rags SIf gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Check SFuel pump operation a Insert the plug 1 to fuel return hose end b Fill the fuel tank c Put the end of the fuel hose into an open con tainer d Connect the battery DC 12 V to the fuel pump couple...

Page 446: ...g light when the main switch is turned ON irrespective of whether the engine is running or not Circuit Defect s System response Condition code Fuel pump thermistor SOpen circuit SShort circuit SThe fuel level warning light indi cate the condition code Refer to 1 Oil level switch SOpen circuit SShort circuit SThe oil level warning light indicate the condition code Refer to 2 1 Condition code Fuel l...

Page 447: ...istor SCheck the fuel pump thermistor for continuity Refer to The fuel level warning light fails to come on SIs the fuel pump thermistor OK YES Replace the fuel pump Replace the multi function meter NOTE 14 Fuel pump 45 Multi function meter TROUBLESHOOTING The warning light starts to indicate the self diagnosis sequence Check 1 fuel pump thermistor 2 oil level switch SBefore troubleshooting remove...

Page 448: ...r replace the wire harness NO 1 Wire harness SCheck the wire harness for continuity Refer to CIRCUIT DIAGRAM SIs the wire harness OK YES Replace the multi function meter B W W W Y L Y B R G Sb W W W G W R W Sb W Sb W A Br Br A R G R G B B R B R B Y B Y B B Y L Y L Dg Ch B G W G W A B W B W G Y B 40 41 42 43 44 45 46 47 48 49 50 51 52 45 Multi function meter 52 Oil level switch 2 Oil level switch C...

Page 449: ...eplacement of parts STARTING FAILURES ENGINE Cylinder s and cylinder head s SLoose spark plug SLoose cylinder head or cylinder SDamaged cylinder head gasket SDamaged cylinder gasket SWorn or damaged cylinder SIncorrect valve clearance SImproperly sealed valve SIncorrect valve to valve seat contact SIncorrect valve timing SFaulty valve spring SSeized valve Piston s and piston ring s SImproperly ins...

Page 450: ...ing SFaulty main switch SFaulty engine stop switch SBroken or shorted wiring SFaulty neutral switch SFaulty start switch SFaulty sidestand switch SFaulty clutch switch SImproperly grounded circuit SLoose connections EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s SIncorrect valve clearance SDamaged valve train components Air filter SClogged air filter element FUEL SYST...

Page 451: ... oil level SIncorrect oil viscosity high SDeteriorated oil EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft SImproperly adjusted shift rod SBent shift shaft Shift drum and shift forks SForeign object in a shift drum groove SSeized shift fork SBent shift fork guide bar Transmission SSeized transmission gear SForeign object between trans...

Page 452: ...r head s and piston s SHeavy carbon buildup Engine oil SIncorrect oil level SIncorrect oil viscosity SInferior oil quality COOLING SYSTEM Coolant SLow coolant level Radiator SDamaged or leaking radiator SFaulty radiator cap SBent or damaged radiator fin Water pump SDamaged or faulty water pump SThermostat SThermostat stays closed SOil cooler SClogged or damaged oil cooler SHose s and pipe s SDamag...

Page 453: ...LTY FRONT FORK LEGS LEAKING OIL SBent damaged or rusty inner tube SCracked or damaged outer tube SImproperly installed oil seal SDamaged oil seal lip SIncorrect oil level high SLoose damper rod assembly bolt SDamaged damper rod assembly bolt copper washer SCracked or damaged cap bolt O ring EAS00863 UNSTABLE HANDLING Handlebars SBent or improperly installed right handlebar SBent or improperly inst...

Page 454: ...HORN DOES NOT SOUND SImproperly adjusted horn SDamaged or faulty horn SFaulty main switch SFaulty horn switch SFaulty battery SBlown damaged or incorrect fuse SFaulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON SWrong headlight bulb SToo many electrical accessories SHard charging SIncorrect connection SImproperly grounded circuit SPoor contacts main or ligh...

Page 455: ...llow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Y W Yellow White YZF R1S YZF R1SC WIRING DIAGRAM 1 Main switch 2 A C magneto 3 Rectifier regulator 4 Fuse main 5 Fuse backup 6 Battery 7 Fuse fuel injection 8 Starter relay 9 Starter motor 10 Starting circuit cut off relay 11 Neutral switch 12 Sidestand switch 13 Fuel pump 14 E C U 15 Ignition coil 1 16 Ignition coil 2 17 Ignition coil 3 1...

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Yamaha YZF-R1S, Service Manual

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