Yamaha YZF-R25 Service Manual Download Page 222

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ENGINE REMOVAL

5-5

Disconnecting the leads and cable

Order

Job/Parts to remove

Q’ty

Remarks

Fuel tank cover assembly/Front side cowling as-
sembly

Refer to “GENERAL CHASSIS (3)” on page
4-5.

Fuel tank

Refer to “FUEL TANK” on page 7-1.

Air filter case

Refer to “GENERAL CHASSIS (6)” on page
4-16.

Throttle bodies

Refer to “THROTTLE BODIES” on page 7-6.

Air cut-off valve/Reed valves

Refer to “AIR INDUCTION SYSTEM” on
page 7-15.

Coolant

Drain.
Refer to “CHANGING THE COOLANT” on
page 3-24.

Coolant reservoir

Refer to “RADIATOR” on page 6-1.

Water pump inlet hose

Refer to “WATER PUMP” on page 6-6.

Radiator inlet hose

Refer to “THERMOSTAT” on page 6-4.

Drive chain

Refer to “CHAIN DRIVE” on page 4-79.

Engine oil

Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-22.

Negative battery lead

Disconnect.

Spark plug cap

Disconnect.

Speed sensor coupler

Disconnect.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

3.5 Nm (0.35 m

•

kgf, 2.5 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

Summary of Contents for YZF-R25

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Page 4: ...ion title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS on page 1 4 A job instruction chart 6 accompanies the exploded diagram provid...

Page 5: ...rviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one Silicone fluid G M BF B T R LS M S LT E New S ...

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Page 7: ...EAS10003 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

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Page 9: ...NCTION METER UNIT 1 4 IMPORTANT INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 RUBBER PARTS 1 10 BASIC SERVICE INFORMATION 1 11 QUICK FASTENERS 1 11 ELECTRICAL SYSTEM 1 12 SPECIAL TOOLS 1 17 ...

Page 10: ...IDENTIFICATION 1 1 EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame under the passenger seat 1 ...

Page 11: ...the en gine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel rat...

Page 12: ... the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air pressure sensor intake air temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that...

Page 13: ...tting the shift timing indicator light control mode Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to the tachometer will sweep across the r min range and then re turn to zero r min in order to test the electrical cir cuit NOTICE ECA19660 Do not op...

Page 14: ...s detected in the electrical circuit the following cycle is repeated until the malfunction is corrected fuel level segments flash eight times then go off for approximately three seconds If this occurs check the electrical circuit Refer to SIGNALING SYSTEM on page 8 19 Coolant temperature meter The coolant temperature meter indicates the temperature of the coolant When the key is turned to the disp...

Page 15: ... L 100 km AVE_ _ _ km L or AVE_ _ _ L 100 km OIL TRIP ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter select it by pushing the SEL button and then push the RES button for at least one second If you do not reset the fuel reserve tripmeter manually it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km 3 mi Instantaneous fuel consumption display The...

Page 16: ...the correct time Shift timing indicator light The shift timing indicator light has four settings which can be adjusted Flashing pattern this function allows you to choose whether or not the indicator light will come on and whether it should flash or stay on when activated Activation point this function allows you to se lect the engine speed at which the indicator light is activated Deactivation po...

Page 17: ... can be set in increments of 200 r min Be sure to set the deactivation point to a higher engine speed than for the activation point oth erwise the shift timing indicator light will not come on 1 Push the RES button to select the desired engine speed for deactivating the indicator light 2 Push the SEL button to confirm the selected engine speed The control mode changes to the brightness setting mod...

Page 18: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 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 and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 19: ...d air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in...

Page 20: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 21: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 22: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 23: ...ure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If ...

Page 24: ...an the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores 6 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03132 Pocket tester 90890 ...

Page 25: ...BASIC SERVICE INFORMATION 1 16 ...

Page 26: ...ing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 14 5 17 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 35 Radiator cap tester...

Page 27: ...er attachment ø41 90890 01381 Replacement 41 mm YM A5142 2 4 67 4 67 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 19 4 72 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 42 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 22 5 71 Damper rod holder 90890 01460 4 64 4 66 Tool name Tool No Illustration Reference pages YU 33984 YM A9409 7 YM A5142 4 ...

Page 28: ...r 90890 03112 Analog pocket tester YU 03112 C 1 15 8 79 8 80 8 80 8 81 8 85 8 86 8 88 8 88 8 88 8 89 8 90 8 91 8 91 8 92 8 93 8 93 8 94 8 94 Pocket tester 90890 03132 1 15 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 11 7 12 Carburetor angle driver 2 90890 03173 3 9 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 44456 ...

Page 29: ...arness S pressure sensor 3P YU 03207 8 92 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 90 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 11 Yamaha diagnostic tool 90890 03231 3 8 3 11 8 34 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 27 5 32 Middle driven shaft bearing driver 90890 04058 M...

Page 30: ...spring compressor adapter 22 mm YM 04108 5 27 5 32 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 29 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 29 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 29 Extension 90890 04136 5 1 Mechanical seal installer 90890 04145 6 8 Tool name Tool No Illustration Reference page...

Page 31: ...g tool 90890 04166 YM 04166 5 42 5 42 5 43 5 44 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 89 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 44 5 72 5 73 Tool name Tool No Illustration Reference pages ...

Page 32: ...SPECIAL TOOLS 1 23 ...

Page 33: ...ENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 33 CABLE ROUTING 2 35 ...

Page 34: ...nsions Overall length 2090 mm 82 3 in Overall width 720 mm 28 3 in Overall height 1135 mm 44 7 in Seat height 780 mm 30 7 in Wheelbase 1380 mm 54 3 in Ground clearance 160 mm 6 30 in Minimum turning radius 2700 mm 106 3 in Weight Curb weight 166 kg 366 lb Maximum load 160 kg 353 lb ...

Page 35: ...L 2 54 US qt 2 11 Imp qt Without oil filter cartridge replacement 1 80 L 1 90 US qt 1 58 Imp qt With oil filter cartridge replacement 2 10 L 2 22 US qt 1 85 Imp qt Oil pressure 206 0 kPa 5000 r min 130 C 29 9 psi 5000 r min 266 F Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 120 mm 0 0047 in Limit Outer rotor to oil pump housing cle...

Page 36: ... 32 150 mm 1 2618 1 2657 in Limit 31 950 mm 1 2579 in Base circle diameter Intake 24 972 25 072 mm 0 9831 0 9871 in Limit 24 872 mm 0 9792 in Lobe height Exhaust 31 650 31 750 mm 1 2461 1 2500 in Limit 31 550 mm 1 2421 in Base circle diameter Exhaust 25 082 25 182 mm 0 9875 0 9914 in Limit 24 982 mm 0 9835 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Tensioning system Automatic Valve v...

Page 37: ...on spring force intake 159 60 183 60 N 16 27 18 72 kgf 35 88 41 27 lbf Installed compression spring force exhaust 159 60 183 60 N 16 27 18 72 kgf 35 88 41 27 lbf Spring tilt intake 1 6 mm 0 06 in Spring tilt exhaust 1 6 mm 0 06 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 60 000 60 010 mm 2 3622 2 3626 in Taper limit 0 050 mm 0 0020 in Out of round limit ...

Page 38: ... bearing clearance 0 021 0 045 mm 0 0008 0 0018 in Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 4 pcs Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 2 pcs Clutc...

Page 39: ...stance Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 192 288 Ω Intake air pressure sensor output voltage 3 88 4 12 V 101 3 kPa 3 88 4 12 V 1 01 kgf cm 3 88 4 12 V 14 7 psi Intake air temperature sensor resistance 5700 6300 Ω 0 C 5700 6300 Ω 32 F Coolant temperature sensor resistance 2513 2777 Ω 20 C 2513 2777 Ω 68 F Idling condition Fuel line pressu...

Page 40: ...17M C 54S Manufacturer model IRC RX 01F Manufacturer model Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 140 70 17M C 66S Manufacturer model IRC RX 01R Manufacturer model Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Front 1 person 200 kPa 2 00 kgf cm 29 psi Rear 1 person 225 kPa 2 25 kgf cm 33 psi Front 2 persons 200 kPa 2 00 kgf cm 29 psi Rear 2 persons 2...

Page 41: ...1 in Specified brake fluid DOT 4 Steering Steering bearing type Center to lock angle left 34 0 Center to lock angle right 34 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring free length 297 8 mm 11 72 in Limit Collar length 229 0 mm 9 02 in Fork spring installed length Spring rate K1 6 45 N mm 0 66 kgf mm 36 83...

Page 42: ...CHASSIS SPECIFICATIONS 2 9 Standard 3 Maximum 7 Drive chain Size manufacturer 520VF DAIDO Number of links 112 15 link length limit Drive chain slack 35 0 45 0 mm 1 38 1 77 in Limit ...

Page 43: ...ut 14 0 V 21 3 A 5000 r min Stator coil resistance 0 216 0 324 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 35 0 A Battery Model GTZ8V Voltage capacity 12 V 7 0 Ah Specific gravity 1 350 Manufacturer GS Ten hour rate charging current 0 70 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 0...

Page 44: ...ndercut depth 1 50 mm 0 06 in Starter relay Amperage 150 0 A Coil resistance 3 06 3 74 Ω Horn Horn type Plane Quantity 1 Maximum amperage 3 5 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 10 0 14 0 Ω Sender unit resistance empty 267 0 273 0 Ω Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 7 5...

Page 45: ...1 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Air filter case joint clamp screw M5 2 2 5 Nm 0 25 m kgf 1 8 ft lbf Air filter case bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Air filter case side cover screw left M5 3 2 5 Nm 0 25 m kgf 1 8 ft lbf Air filter case side cover screw right M5 8 1 3 Nm 0 13 m kgf 0 94 ft lbf Spark plug M10 2 13 Nm 1 3 m kgf 9 4 ft lbf O2 sensor M12 1 ...

Page 46: ... 0 35 m kgf 2 5 ft lbf Starter motor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter motor front cover bolt M4 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Brush holder screw M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Clutch boss nut M18 1 100 Nm 10 m kgf 72 ft lbf Clutch spring bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cover bolt M6 7 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Sh...

Page 47: ...od nut M6 4 See TIP Shift fork guide bar retainer bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Shift drum segment screw M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Radiator bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Radiator fan cover bolt M6 3 8 Nm 0 8 m kgf 5 8 ft lbf Coolant reservoir cover bolt M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Radiator outlet hose clamp screw M5 1 2 0 Nm 0 20 m kgf 1 4 ft lbf Radiator inlet hose clamp...

Page 48: ...o 1215 to the bolt threads 3 Tighten the crankcase bolts 1 6 to 20 Nm 2 0 m kgf 14 ft lbf 4 Loosen and retighten the crankcase bolts 1 6 to 24 Nm 2 4 m kgf 17 ft lbf in the proper tight ening sequence 5 Tighten the crankcase bolts 7 8 to 20 Nm 2 0 m kgf 14 ft lbf 6 Loosen and retighten the crankcase bolts 7 8 to 26 Nm 2 6 m kgf 19 ft lbf in the proper tight ening sequence 7 Tighten the crankcase b...

Page 49: ...TIGHTENING TORQUES 2 16 2 6 8 5 4 1 2 6 3 7 2 10 9 A ...

Page 50: ...ounting nut rear upper side M10 1 68 Nm 6 8 m kgf 49 ft lbf Sidestand bolt M10 2 66 Nm 6 6 m kgf 48 ft lbf Engine mounting nut rear lower side M10 1 68 Nm 6 8 m kgf 49 ft lbf Engine mounting bolt right front side M10 1 68 Nm 6 8 m kgf 49 ft lbf Engine mounting bolt left front side M10 1 68 Nm 6 8 m kgf 49 ft lbf Engine bracket bolt right M10 2 68 Nm 6 8 m kgf 49 ft lbf Engine bracket bolt left M10...

Page 51: ... lbf Front upper cowling nut left side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front upper cowling screw M5 4 1 8 Nm 0 18 m kgf 1 3 ft lbf Front upper cowling bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front lower cowling screw M5 2 1 8 Nm 0 18 m kgf 1 3 ft lbf Rearview mirror bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bolt M8 2 33 Nm 3 3 m kgf 24 ft lbf Meter assembly bracket bolt M6 2 7 Nm 0 7 m...

Page 52: ...0 m kgf 22 ft lbf Rear brake master cylinder bolt M8 2 23 Nm 2 3 m kgf 17 ft lbf Brake pedal bolt M10 1 30 Nm 3 0 m kgf 22 ft lbf Rear brake hose guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake pedal adjusting locknut M8 2 17 Nm 1 7 m kgf 12 ft lbf Grip end bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Handlebar switch screw right M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Throttle cable guide screw handle bar ...

Page 53: ...7 2 ft lbf Pivot shaft nut M16 1 115 Nm 11 5 m kgf 83 ft lbf Drive sprocket cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Drive sprocket nut M20 1 75 Nm 7 5 m kgf 54 ft lbf Shift arm pinch bolt M6 1 14 Nm 1 4 m kgf 10 ft lbf Shift rod locknut shift arm side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Shift rod locknut shift pedal side M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Left hand threads Shift pedal bolt M10 1 30 Nm 3...

Page 54: ... exhaust Valve stem ends intake and exhaust Valve lifter surfaces Valve stem seals Timing chain tensioner outer surface Oil pump rotors inner and outer Oil pump shaft Oil filter cartridge union bolt Oil strainer seal or Oil pump idle gear shaft Oil pump idle gear inner and thrust surfaces Starter clutch idle gear thrust surfaces Starter clutch rollers and starter clutch gear boss Starter clutch id...

Page 55: ...d pinion and collar Transmission gears inner surface shift fork contact parts Shift fork and transmission gear contact surface Shift drum assembly Shift forks and shift fork guide bars Shift shaft moving surface Shift shaft washer Lubrication point Lubricant M M M E E E E ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 1 2 7 3 4 5 6 8 9 10 11 12 13 14 15 ...

Page 57: ...trainer 2 Oil pump 3 Relief valve 4 Oil filter cartridge 5 Sub gallery 6 Main gallery 7 Crankshaft 8 Oil nozzle 9 Balancer shaft assembly 10 Timing chain tensioner 11 Intake camshaft 12 Exhaust camshaft 13 Main axle 14 Transmission shower 15 Drive axle ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS30021 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head right side view 3 2 1 9 8 7 6 5 4 1 Timing chain tensioner 2 Intake camshaft ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 3 Exhaust camshaft 4 Crankshaft 5 Balancer shaft assembly 6 Oil filter cartridge 7 Oil strainer 8 Oil pump 9 Transmission shower ...

Page 60: ...ICATION SYSTEM CHART AND DIAGRAMS 2 27 Crankcase and cylinder left side view 6 3 2 1 5 4 1 Crankshaft 2 Balancer shaft assembly 3 Connecting rod 4 Oil drain bolt 5 Oil filter cartridge 6 Oil pressure switch ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 Oil pump right side view 1 2 1 Oil pump 2 Relief valve ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 Oil strainer bottom view 2 3 1 4 1 Main gallery 2 Oil filter cartridge 3 Sub gallery 4 Oil strainer ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 Camshaft top view 2 3 1 1 Intake camshaft 2 Exhaust camshaft 3 Cylinder head ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 Crankshaft rear view 1 2 3 3 4 5 1 Crankshaft 2 Oil nozzle 3 Piston 4 Main gallery 5 Sub gallery ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 Crankshaft and transmission top view 1 2 3 4 1 Crankshaft 2 Balancer shaft assembly 3 Main axle 4 Drive axle ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20020 COOLING SYSTEM DIAGRAMS 1 2 3 1 5 4 4 ...

Page 67: ...COOLING SYSTEM DIAGRAMS 2 34 1 Radiator 2 Radiator outlet hose 3 Water pump 4 Thermostat 5 Radiator inlet hose ...

Page 68: ...ING 2 35 EAS20021 CABLE ROUTING Handlebar front view M 5 9 J 9 L K 9 11 1 2 3 4 5 6 7 9 10 11 A B C E F A D I 6 7 13 14 14 13 14 14 12 8 G H 9 1 Throttle cable accelerator cable 2 Throttle cable decelerator cable ...

Page 69: ...ead to the front of the front brake hose Make sure that the plastic band contacts the pipe section of the front brake hose F The main switch lead left handlebar switch lead and right handlebar switch lead may be routed in any order G Route the horn lead to the outside of the front brake hose H Route the main switch left handlebar switch and right handlebar switch leads according to instructions J ...

Page 70: ...5 1 11 12 6 16 17 18 19 F 1 2 3 4 5 6 7 8 9 A B C 2 21 G H 20 10 1 Negative battery sub wire harness coupler 2 Fuel tank drain hose 3 Ignition coil lead 4 Headlight lead right 5 Front turn signal light lead right turn signal light 6 Coolant reservoir hose ...

Page 71: ... pressure switch lead gear position switch lead O2 sensor lead negative battery sub wire harness and starter motor lead with the holder The leads may be fastened in any order E Fasten the speed sensor lead O2 sensor lead and negative battery sub wire harness with the holder The leads may be fastened in any order F Install the radiator fan motor relay and headlight relay completely onto the tabs on...

Page 72: ...TING 2 39 Rear fender right side view 1 2 3 4 5 7 7 5 6 3 B E A B C D 6 9 8 10 10 1 Fuse box 2 Rear fender 3 Fuse box lead 4 Rear brake light switch coupler 5 Rear brake light switch lead 6 Fuel tank drain hose ...

Page 73: ...s end of the plastic locking tie to 3 mm 0 12 in or less C Route the rear brake light switch lead to the front of the frame cross member D Route the fuel tank drain hose between the stay and the engine stay E Fasten the rear brake light switch lead at the white tape to the down tube with a plastic locking tie Make sure that the plastic locking tie contacts the frame reinforcement Face the buckle o...

Page 74: ...side view 1 2 3 3 4 5 6 7 12 11 2 A C B D G H I J K 16 17 2 19 Q F 14 15 E 13 8 9 M N O 7 2 18 L P 7 18 18 2 10 10 1 Auxiliary light lead 2 Fuel tank breather hose 3 Guide 4 Coolant reservoir hose 5 O2 sensor lead 6 O2 sensor coupler ...

Page 75: ...0 12 in or less G Fasten the main switch lead left handlebar switch lead and right handlebar switch lead at the white tape on each lead with a plastic locking tie H Fasten the main switch lead left handlebar switch lead and right handlebar switch lead with a plastic locking tie as shown in the illustration Fit the end of the plastic locking tie into the electrical components tray I The main switch...

Page 76: ...A B C D E F G H I 14 15 15 J K L M 14 14 14 15 7 16 17 17 O I P 18 19 20 21 N 22 25 24 23 13 1 Coolant reservoir breather hose 2 Gear position switch coupler 3 Starting circuit cut off relay 4 Starter motor lead terminal 5 Starter relay coupler 6 Yamaha diagnostic tool coupler ...

Page 77: ...stic locking ties G The stator coil lead and gear position switch lead may be routed in any order H Fasten the starter motor lead negative battery sub wire harness stator coil lead and gear position switch lead to the wire harness with a plastic locking tie as shown in the illustration Face the buckle of the plastic locking tie outward with the end pointing upward Cut off the excess end of the pla...

Page 78: ... 16 17 18 19 19 A B B C 11 23 D D 4 22 26 L 26 L J J I 19 8 9 E K 24 25 H 19 E F G 14 21 20 1 Clutch cable 2 Handlebar switch lead left handlebar switch 3 Front turn signal light lead left turn signal light 4 Headlight lead left 5 Auxiliary light lead 6 Meter assembly ...

Page 79: ...the projection on the plastic locking tie into the hole in the electrical components tray F The main switch lead left handlebar switch lead and right handlebar switch lead may be routed in any order G Fasten the main switch lead left handlebar switch lead and right handlebar switch lead at the white tape on each lead with the plastic locking tie Point the end of the plastic locking tie outward Cut...

Page 80: ... 4 5 6 7 8 9 10 3 11 12 13 14 15 16 17 18 19 20 21 22 23 23 23 24 25 26 27 28 A B C D E F G 18 B 3 7 9 29 30 4 H I J 1 Fuel tank drain hose 2 O2 sensor lead 3 Negative battery sub wire harness 4 Frame 5 Rear brake light switch lead 6 Fuse box lead ...

Page 81: ...ert the projection on the wire harness holder into the hole in the frame C Fit the turn signal relay into the hole in the ECU band D Route the negative battery sub wire harness under the ECU engine control unit E Route the rear turn signal light leads license plate light lead and Yamaha diagnostic tool coupler lead through the guide on the rear fender F Fasten the wire harness to the frame with a ...

Page 82: ...iew A B 1 3 2 1 1 1 2 1 Front brake hose 2 Front brake caliper 3 Guide A Route the front brake hose over the guide B When installing the brake hose onto the brake caliper make sure that the brake pipe touches the projection on the brake caliper ...

Page 83: ...ABLE ROUTING 2 50 Rear brake right side view 1 2 3 4 2 B C D A 1 Rear brake caliper 2 Brake hose rear brake master cylinder to rear brake caliper 3 Brake fluid reservoir hose 4 Rear brake master cylinder ...

Page 84: ...r on the rear brake master cylinder make sure that the brake pipe touches the projection on the master cylinder C Connect the end of the brake hose rear brake master cylinder to rear brake caliper that is identified by the white paint mark to the rear brake master cylinder D When installing the brake hose onto the brake caliper make sure that the brake pipe touches the projection on the brake cali...

Page 85: ... 52 Fuel tank left side view A B C D E F G H 1 2 3 4 5 6 7 8 6 1 1 2 1 Fuel tank 2 Fuel hose fuel tank to fuel rail 3 Fuel pump 4 Fuel tank breather hose fuel tank to hose joint 5 Fuel tank breather hose 6 Hose joint ...

Page 86: ...uel tank to hose joint so that it contacts the tapered portion of the hose fitting on the fuel tank and it contacts the stopper on the hose joint F Align the yellow paint mark on the fuel tank breather hose with the yellow paint mark on the fuel tank breather hose fuel tank to hose joint G Align the yellow paint mark on the fuel tank drain hose with the yellow paint mark on the fuel tank drain hos...

Page 87: ...left and right view A B C D E F G H I J K 1 2 4 5 6 1 3 3 6 1 1 ISC idle speed control valve inlet hose 2 Air filter case assembly 3 Crankcase breather hose 4 Crankcase breather cover 5 Throttle bodies 6 Fuel hose fuel tank to fuel rail ...

Page 88: ...he hose fitting E Forward F Install the hose clamp as shown in the illustration so that one end of the clamp is pointing rearward and one end is pointing inward G 0 3 mm 0 0 12 in H Connect the black connector of the fuel hose fuel tank to fuel rail to the fuel rail I Point the ends of the hose clamp downward J Face the white paint mark on the ISC idle speed control valve inlet hose to the right K...

Page 89: ...op view E 2 2 F 3 4 E 3 1 E 1 5 C D 4 B A 3 2 1 Reed valve cover 2 Air induction system hose air cut off valve to reed valve cover 3 Air cut off valve 4 Air induction system hose air filter case to air cut off valve 5 Air filter case assembly ...

Page 90: ...m hose air filter case to air cut off valve upward C Face the white paint mark on the air induction system hose air filter case to air cut off valve upward D Point the ends of the hose clamp downward E Install the hose completely onto the hose fitting F Point the ends of the hose clamp to the forward angled downward ...

Page 91: ... Radiator top view B C G I D J K L 1 2 3 4 5 6 7 8 1 3 4 3 H D 6 5 6 4 6 8 D F E A 1 Radiator 2 Radiator outlet hose 3 Coolant reservoir hose 4 Coolant reservoir cap 5 Coolant reservoir breather hose 6 Coolant reservoir ...

Page 92: ... Downward F Install the coolant reservoir hose until the end of the hose contacts the raised portion of the hose fitting G 10 mm 0 39 in or more H 5 mm 0 20 in I Install the pipe up to the groove in the coolant reservoir cap J Install the coolant reservoir breather hose completely onto the hose fitting of the coolant reservoir K Left side L Install the coolant hose so that the end of the hose is p...

Page 93: ... 2 60 Radiator left side view A B D H I J E F 1 2 3 4 5 6 7 8 9 7 2 1 G 7 C 1 Coolant reservoir hose 2 Electrical components tray 3 Coolant reservoir cap 4 Coolant reservoir breather hose 5 Frame 6 Coolant reservoir ...

Page 94: ...servoir breather hose outward C Install the radiator inlet hose completely onto the hose fitting of the thermostat cover D Connect the end of the radiator inlet hose that is identified by the white paint mark to the radiator E White paint mark F Install the radiator inlet hose up to the projection on the hose fitting G Outward H Insert the projection on the holder into the hole in the electrical c...

Page 95: ...CABLE ROUTING 2 62 Radiator right side view A B C D E F 1 2 3 4 3 3 3 1 Coolant reservoir hose 2 Radiator 3 Radiator outlet hose 4 Water pump housing ...

Page 96: ... to the radiator B Install the radiator outlet hose completely onto the hose fitting of the water pump housing C Outward D White paint mark E Install the radiator outlet hose up to the projection on the hose fitting F The fastener of the screw clamp should be facing forward with the screw head facing outward ...

Page 97: ... CHECKING THE FUEL FILTER 3 4 CHECKING THE SPARK PLUGS 3 4 ADJUSTING THE VALVE CLEARANCE 3 5 CHECKING THE ENGINE IDLING SPEED 3 8 SYNCHRONIZING THE THROTTLE BODIES 3 8 CHECKING THE THROTTLE BODY JOINT 3 10 CHECKING THE EXHAUST SYSTEM 3 10 ADJUSTING THE EXHAUST GAS VOLUME 3 11 CHECKING THE CRANKCASE BREATHER HOSE 3 11 CHECKING THE AIR INDUCTION SYSTEM 3 11 REPLACING THE AIR FILTER ELEMENT AND CLEAN...

Page 98: ...ERING HEAD 3 19 LUBRICATING THE STEERING HEAD 3 20 CHECKING THE CHASSIS FASTENERS 3 20 LUBRICATING THE BRAKE LEVER 3 20 LUBRICATING THE PEDAL 3 20 LUBRICATING THE CLUTCH LEVER 3 20 CHECKING THE SIDESTAND 3 20 LUBRICATING THE SIDESTAND 3 20 CHECKING THE FRONT FORK 3 20 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 3 20 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 21 CHECKING THE ENGINE OIL LEVEL 3 21 C...

Page 99: ......

Page 100: ...ry year except if a kilometer based maintenance is performed instead From 25000 km or 25 months repeat the maintenance intervals starting from 5000 km or 5 months Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km ...

Page 101: ...ricate chain with a special O ring chain lu bricant thoroughly Every 1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing play and steer ing for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 16 Brake lever pivot s...

Page 102: ...l tank be careful not to pull the fuel tank overflow hose and fuel tank breather hose 3 Check Fuel hose 1 Fuel tank overflow hose 2 Fuel tank breather hose 3 Cracks damage Replace Loose connection Connect properly NOTICE ECA16950 Make sure the fuel tank breather overflow hose is routed correctly 24 Engine oil filter cartridge Replace 25 Cooling system Check coolant level and vehi cle for coolant l...

Page 103: ...Fuel tank cover assembly Refer to GENERAL CHASSIS 3 on page 4 5 Side panels Refer to GENERAL CHASSIS 2 on page 4 3 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Side panels Refer to GENERAL CHASSIS 2 on page 4 3 Fuel tank cover assembly Refer to...

Page 104: ...E The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engine at room temperature 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Side panels Refer to GENERAL CHASSIS 2 on page 4 3 Fuel tank cover assembly Front side cowling assembly right Refer to GENERAL CHASSIS 3 on page 4 5 Water pump housing Refer to WATER PUMP on page 6 6 Clu...

Page 105: ... piston 1 is at 90 ATDC d Measure the valve clearance with a thickness gauge 1 TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence 6 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 11 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 7 Adjust Valve c...

Page 106: ...2 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 58 mm 0 0622 in 0 07 mm 0 0028 in 1 65 mm 0 0649 in The valve pad number is 165 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Examp...

Page 107: ...or several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the ISC idle speed control valve Refer to CHECKING THE THROTTLE BODIES AND ISC IDLE SPEED CON TROL VALVE on page 7 8 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DI...

Page 108: ...throttle body 1 as standard adjust throttle body 2 using the air screw 1 TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization ca...

Page 109: ...ies Refer to THROTTLE BODIES on page 7 6 3 Check Throttle body joint 1 Cracks damage Replace 4 Install Throttle bodies Refer to THROTTLE BODIES on page 7 6 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover assembly Refer to GENERAL CHASSIS 3 on page 4 5 Side panels Refer to GENERAL CHASSIS 2 on page 4 3 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30625 CHECKING THE EXHAUS...

Page 110: ... RADIATOR on page 6 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Coolant reservoir Refer to RADIATOR on page 6 1 Front bottom cowling left Refer to GENERAL CHASSIS 3 on page 4 5 Side panel left Refer to GENERAL CHASSIS 2 on page 4 3 EAS30627 CHECKING THE AIR INDUCTION ...

Page 111: ...may damage the engine Operating the engine without the air filter element will also affect throttle body synchronization leading to poor engine per formance and possible overheating 6 Install Side panel left Refer to GENERAL CHASSIS 2 on page 4 3 EAS30816 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 82 EAS30629 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check ...

Page 112: ...801 CHECKING THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check the brake system Refer to FRONT BRAKE on page 4 30 and REAR BRAKE on page 4 42 TIP Drive on the dry road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate ...

Page 113: ...eakage Replace the damaged hose Refer to REAR BRAKE on page 4 42 EAS30637 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA13100 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or br...

Page 114: ...rake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 EAS30632 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may...

Page 115: ... Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident...

Page 116: ...ECKING THE REAR WHEEL on page 4 27 EAS30802 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY on page 4 74 2 Check Swingarm excessive play Refer to SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY on page 4 74 EAS30643 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Bearings Spacer Dust covers Refer to...

Page 117: ...ate and the adjusting nuts c Tighten the wheel axle nut to specification d Tighten the drive chain puller adjusting nuts and the drive chain puller locknuts to specifi cation EAS30803 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the ...

Page 118: ...en it to specification with a steering nut wrench 5 TIP Set the torque wrench at a right angle to the steering nut wrench c Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any bindi...

Page 119: ...lace EAS30651 LUBRICATING THE SIDESTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact point of the side stand EAS30653 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and out...

Page 120: ...he engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled NOTICE ECA13361 Engine oil also lubricates the clutch and...

Page 121: ...n bolt 2 along with the gasket 3 4 Drain Engine oil completely from the oil pan 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil NOTICE ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of th...

Page 122: ...again e Tighten the oil check bolts to specification EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the min imum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA1...

Page 123: ...page 4 5 3 Remove Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the 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 counter clockwise toward the...

Page 124: ...illed water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install Radiator cap 12 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Coolant reservoir cap Coolant reservoir cover Refer to RADIATOR on page 6 1 14 Connect Front turn sign...

Page 125: ...ng procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or u...

Page 126: ...vered com pletely by the rubber cover EAS30663 CHECKING THE SWITCHES LIGHTS AND SIGNALS 1 Check that all switches operate and that all lights come on Refer to INSTRUMENT AND CONTROL FUNCTIONS in Owner s manual Faulty Refer to CHECKING THE SWITCHES on page 8 77 and CHECKING THE BULBS AND BULB SOCKETS on page 8 79 EAS30665 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the ...

Page 127: ...glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Hook Headlight bulb holder 7 Connect Headlight coupler 8 Install Headlight bulb cover 1 TIP Be sure to align the mark a on the headlight bulb cover with the mark b on the headlight EAS30664 ADJUSTING THE HEADLIGHT...

Page 128: ...PERIODIC MAINTENANCE 3 29 ...

Page 129: ...RONT BOTTOM COWLINGS 4 8 INSTALLING THE FRONT BOTTOM COWLINGS 4 8 REMOVING THE FRONT SIDE COWLING ASSEMBLY 4 9 INSTALLING THE FRONT SIDE COWLING ASSEMBLY 4 10 REMOVING THE FRONT UPPER COWLING 4 10 INSTALLING THE FRONT UPPER COWLING 4 10 GENERAL CHASSIS 4 4 11 INSTALLING THE FRONT COWLING ASSEMBLY 4 12 GENERAL CHASSIS 5 4 13 REMOVING THE WINDSHIELD ASSEMBLY 4 14 INSTALLING THE WINDSHIELD ASSEMBLY 4...

Page 130: ... MASTER CYLINDER 4 39 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 40 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 40 REAR BRAKE 4 42 INTRODUCTION 4 48 CHECKING THE REAR BRAKE DISC 4 48 REPLACING THE REAR BRAKE PADS 4 48 REMOVING THE REAR BRAKE CALIPER 4 50 DISASSEMBLING THE REAR BRAKE CALIPER 4 50 CHECKING THE REAR BRAKE CALIPER 4 50 ASSEMBLING THE REAR BRAKE CALIPER 4 51 INSTALLING THE REAR BRAK...

Page 131: ...HE REAR SHOCK ABSORBER ASSEMBLY 4 76 REMOVING THE SWINGARM 4 76 CHECKING THE SWINGARM 4 76 INSTALLING THE SWINGARM 4 77 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 CHAIN DRIVE 4 79 REMOVING THE DRIVE CHAIN 4 80 CHECKING THE DRIVE CHAIN 4 80 CHECKING THE DRIVE SPROCKET 4 81 CHECKING THE REAR WHEEL SPROCKET 4 81 CHECKING THE REAR WHEEL DRIVE HUB 4 81 INSTALLING THE DRIVE SPROCKET 4 81 INSTALLIN...

Page 132: ... to remove Q ty Remarks 1 Passenger seat 1 2 Owner s tool kit 1 3 Center cover 1 4 Rider seat 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery band 1 8 Battery 1 9 Battery seat 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 6 4 8 7 5 9 2 1 ...

Page 133: ...ert the projection a on the front of the rider seat into the hole b as shown EAS31190 INSTALLING THE CENTER COVER 1 Install Center cover 1 TIP Fit the projections a on the center cover into the rear upper side cowlings EAS31126 INSTALLING THE PASSENGER SEAT 1 Install Passenger seat 1 TIP Insert the projections a on the front of the pas senger seat into the grooves b as shown and then push the rear...

Page 134: ...nel 1 4 Seat lock 1 5 Rear side cowling assembly left 1 6 Rear lower side cowling left 1 7 Key cylinder 1 8 Rear upper side cowling left 1 9 Rear side cowling assembly right 1 10 Rear lower side cowling right 1 11 Rear upper side cowling right 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf...

Page 135: ...b on the panel into the grommets and then tighten the side panel bolts EAS31292 REMOVING THE UPPER TAIL PANEL 1 Remove Upper tail panel 1 a Remove the upper tail panel screws b Slide the upper tail panel rearward and re move it EAS31293 INSTALLING THE UPPER TAIL PANEL 1 Install Upper tail panel 1 a Fit the projections a on the upper tail panel into the holes b in the rear lower side cowl ings and ...

Page 136: ...r to GENERAL CHASSIS 2 on page 4 3 1 Front panel left 1 2 Front panel right 1 3 Fuel tank cover assembly 1 4 Fuel tank cover left 1 5 Fuel tank cover right 1 6 Fuel tank cover center 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 4 6 5 3 2 ...

Page 137: ...e cowling left 1 9 Front bottom cowling right 1 10 Front side cowling assembly right 1 11 Front turn signal light connector right 2 Disconnect 12 Front side cowling inner panel right 1 13 Front upper cowling right 1 14 Front lower cowling right 1 15 Front side cowling right 1 2 7 5 4 8 1 14 11 15 10 3 9 13 6 12 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 138: ...ck fasten ers and then tighten the bolts to specifica tion EAS31354 DISASSEMBLING THE FUEL TANK COVER ASSEMBLY The following procedure applies to both of the fuel tank side covers 1 Remove the projections a on the fuel tank side cover 1 from the holes b in the fuel tank center cover 2 EAS31355 ASSEMBLING THE FUEL TANK COVER ASSEMBLY The following procedure applies to both of the fuel tank side cov...

Page 139: ...a Remove the front bottom cowling bolts b Remove the projection a on the front bottom cowling from the hole b in the front side cowling c Slide the front bottom cowling downward to remove the projections c on the front bottom cowling from the holes d in the front side cowling and to remove the projection e on the front upper cowling from the hole f in the front bottom cowling and then remove the f...

Page 140: ...nt side cowling assembly Remove the quick fastener 2 screw 3 and bolts 4 Right front side cowling as sembly b Remove the projection a on the front side cowling assembly from the grommet c Remove the portion b of the front cowling in ner panel from the slot c in the front side cowling assembly and then slide the front side cowling assembly forward to remove the projections d on the front side cowli...

Page 141: ...cation Right front side cowling assembly EAS31362 REMOVING THE FRONT UPPER COWLING The following procedure applies to both of the front upper cowling 1 Remove Front upper cowling 1 TIP Slide the front upper cowling in the direction of the arrow shown in the illustration to remove the projections a on the front side cowling 2 from the holes b in the front upper cowling EAS31363 INSTALLING THE FRONT...

Page 142: ...owling assemblies Refer to GENERAL CHASSIS 3 on page 4 5 1 Rearview mirror 2 2 License plate bracket 1 3 Meter assembly coupler 1 Disconnect 4 Headlight coupler left 1 Disconnect 5 Headlight coupler right 1 Disconnect 6 Auxiliary light coupler 1 Disconnect 7 Front cowling assembly 1 33 Nm 3 3 m kgf 24 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 7 5 3 4 1 1 2 ...

Page 143: ...296 INSTALLING THE FRONT COWLING ASSEMBLY 1 Install Front cowling assembly TIP Fit the projection a on the front cowling assem bly bracket into the hole b in the frame T R Front cowling assembly bolt 33 Nm 3 3 m kgf 24 ft lbf b a ...

Page 144: ... 5 Windshield 1 6 Front cowling center cover 1 7 Front cowling inner panel 1 8 Headlight bulb cover 2 9 Headlight coupler 2 Disconnect 10 Headlight bulb 2 11 Front cowling assembly bracket 1 12 Headlight assembly 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R New New 3 2 12 7 11 9 ...

Page 145: ... the illustration c Install the windshield assembly screws and then tighten the screws to specification EAS31299 REMOVING THE FRONT COWLING CENTER COVER 1 Remove Front cowling center cover 1 TIP Slide the front cowling center cover in the direc tion of the arrow shown in the illustration to re move the projections a on the windshield 2 from the holes b in the front cowling center cov er EAS31300 I...

Page 146: ...GENERAL CHASSIS 5 4 15 1 b b a a 2 ...

Page 147: ...2 Air filter element 1 3 Air filter case joint clamp screw 2 Loosen 4 Air filter case assembly 1 5 Air induction system hose Air filter case side cover right to air cut off valve 1 6 ISC idle speed control valve inlet hose 1 7 Crankcase breather hose 1 8 Air filter case side cover right 1 9 Air filter check hose 1 10 Air filter case 1 1 2 9 10 6 7 New New 8 8 4 5 3 3 1 3 Nm 0 13 m kgf 0 94 ft Ibf ...

Page 148: ...CASE 1 Install Air filter case joint clamps 1 TIP Align the projection a on the air filter case joint with the slot b in the air filter case joint clamp T R Air filter case joint clamp screw 2 5 Nm 0 25 m kgf 1 8 ft lbf A Right side B Left side 1 b a a b 1 A B ...

Page 149: ...Q ty Remarks 1 Front brake hose holder 1 2 Front brake caliper 1 3 Front wheel axle nut 1 4 Front wheel axle 1 5 Front wheel 1 6 Collar 2 7 Front brake disc 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R LT LS New 1 2 3 4 6 6 5 5 7 ...

Page 150: ...FRONT WHEEL 4 19 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing right 1 3 Wheel bearing left 1 4 Spacer 1 LS LS New New New New 1 2 3 1 4 ...

Page 151: ...bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP 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 EAS30147 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to...

Page 152: ...lace a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 EAS30152 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance w...

Page 153: ... Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS309...

Page 154: ...40 Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smooth ly 6 Install Front brake caliper Front brake hose holder 1 WARNING EWA13500 Make sure the brake hose is routed properly TIP While holding the front brake hose holder so that the portion a of the holder contacts the portion b of the front fork tighten the front brake h...

Page 155: ... wheel axle nut 1 8 Washer 2 9 Rear wheel axle 1 10 Rear wheel 1 11 Brake caliper bracket 1 12 Brake caliper retaining bolt 1 13 Chain puller 2 14 Collar left 1 15 Collar right 1 7 8 9 1 11 15 14 13 13 6 12 5 4 3 6 5 4 3 2 10 8 2 LS S S 23 Nm 2 3 m kgf 17 ft Ibf T R 57 Nm 5 7 m kgf 41 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 31 Nm 3 1 m kgf 22 ft Ibf T R 1 5 Nm 0 15 m...

Page 156: ... Plate 3 3 Bracket 1 1 4 Bracket 2 1 5 Rear wheel sprocket 1 6 Rear wheel drive hub 1 7 Oil seal 1 8 Bearing 1 9 Collar 1 10 Rear wheel drive hub damper 6 11 Rear brake disc 1 12 Rear wheel 1 LT LT LT New New LS LS LT LS 12 1 3 5 8 7 2 4 2 6 6 9 10 11 3 6 68 Nm 6 8 m kgf 49 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R ...

Page 157: ...REAR WHEEL 4 26 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing right 1 3 Wheel bearing left 1 4 Spacer 1 New LS New New 1 2 3 4 ...

Page 158: ...WHEEL 1 Remove Oil seal Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 20 EAS30159 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Wheel bearings Oil seal Refer to CHECKING THE FRONT WHEEL on page 4 20 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 16 and CHECKING THE WHEELS on page 3 16 3 Measure Radial wheel runout Lateral wheel runout Refer to...

Page 159: ...Refer to ASSEMBLING THE FRONT WHEEL on page 4 21 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 21 EAS30165 INSTALLING ...

Page 160: ... b in the swingarm with the slot c of the brake caliper bracket Apply lithium soap based grease to the con tact surface and threads of the rear wheel axle nut 6 Lubricate Rear brake caliper bolt 7 Install Rear brake caliper Rear brake caliper bolt 8 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 9 Tighten Rear wheel axle nut Rear brake caliper bolt WARNING EWA13500 ...

Page 161: ...ts to remove Q ty Remarks 1 Front brake caliper bolt 2 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad inner 1 6 Brake pad outer 1 7 Brake pad spring 1 8 Brake caliper bleed screw 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 1 7 5 6 4 3 2 8 ...

Page 162: ...r diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt master cylinder side 1 8 Brake hose gasket 2 9 Brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 1 2 3 11 5 6 4 8 9 7 10 LT S New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 1 Nm 0 11 m kgf 0 80 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1...

Page 163: ...FRONT BRAKE 4 32 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 New BF S BF 2 1 ...

Page 164: ...Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 1 Front brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Brake hose 1 4 Front brake caliper bolt 2 5 Front brake caliper 1 35 Nm 3 5 m kgf 25 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R New 1 2 5 4 3 ...

Page 165: ...rake pad pin 1 3 Brake pad inner 1 4 Brake pad outer 1 5 Brake pad spring 1 6 Front brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Brake caliper bleed screw 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R S S S S New New New New BF BF S 9 10 8 8 9 6 7 7 1 5 3 4 2 ...

Page 166: ...e disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at...

Page 167: ...er 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad spring Brake pads TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with yo...

Page 168: ... system 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons 1 Brake caliper piston dust seals 2 Brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening a to force out the pistons from the ...

Page 169: ... brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS30934 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brake caliper 1 temporarily Brake hose gaskets 2 Brake hose 3 Brake hose union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA18220 When installing the brake hose onto the br...

Page 170: ... Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 EAS30179 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Front brake light switch connectors from the...

Page 171: ... between the bottom of the handlebar right and the bottom of the front brake master cylin der is 11 mm 0 43 in as shown in the illustra tion First tighten the upper bolt then the lower bolt 2 Install Brake hose Brake hose gaskets Brake hose union bolt WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation TIP Attach the brake hose so that its angle is 75 to 85 ag...

Page 172: ...enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 5 Check Brake fluid level Below the minimum leve...

Page 173: ...Remarks 1 Brake pad pin 1 2 Rear brake caliper bolt 1 3 Brake pad inner 1 4 Brake pad shim inner 1 5 Brake pad outer 1 6 Brake pad shim outer 1 7 Rear brake caliper 1 8 Brake pad spring 1 9 Brake caliper bleed screw 1 S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 6 4 5 2 1 7 3 8 9 ...

Page 174: ...hragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt master cylinder side 1 8 Brake hose gasket 2 9 Brake hose 1 Disconnect 10 Rear brake light switch coupler 1 Disconnect 11 Rear brake light switch 1 12 Footrest assembly right 1 13 Rear brake master cylinder 1 LT LS 12 14 11 13 15 7 8 9 New New 2 10 3 4 5 1 6 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 ...

Page 175: ...r Order Job Parts to remove Q ty Remarks LT LS 12 14 11 13 15 7 8 9 New New 2 10 3 4 5 1 6 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 176: ... rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Brake master cylinder body 1 17 Nm 1 7 m kgf 12 ft Ibf T R S New New New BF BF 4 2 1 2 3 ...

Page 177: ...ING THE HYDRAULIC BRAKE SYSTEM on page 3 14 1 Rear brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Brake hose 1 4 Brake pad pin 1 5 Rear brake caliper bolt 1 6 Brake pad inner 1 7 Brake pad outer 1 8 Rear brake caliper 1 S New 23 Nm 2 3 m kgf 17 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R 7 4 5 8 3 2 1 6 ...

Page 178: ...er Order Job Parts to remove Q ty Remarks 1 Brake pad spring 1 2 Brake caliper piston 1 3 Brake caliper piston dust seal 1 4 Brake caliper piston seal 1 5 Brake caliper bleed screw 1 6 Spacer 1 S S S New New BF 6 Nm 0 6 m kgf 4 3 ft Ibf T R 2 4 5 3 1 6 ...

Page 179: ...EEL on page 4 24 2 Check Rear brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 35 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4...

Page 180: ... contact the brake pads Remove any excess grease TIP The longer tangs a of the brake pad spring must point in the direction of the brake caliper piston 3 Lubricate Rear brake caliper bolt NOTICE ECA18210 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Rear brake caliper bolt 5 Check Brake fluid level Below the minimum level mark a Add the specifi...

Page 181: ...hen the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks ...

Page 182: ...ricate Rear brake caliper bolt 2 Install Brake pad shims onto the brake pads Brake pads Rear brake caliper 1 Refer to REPLACING THE REAR BRAKE PADS on page 4 48 Brake hose gaskets 2 Brake hose 3 Rear brake hose union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper 1 make sure the ...

Page 183: ...mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP To collect any remaining brake flui...

Page 184: ...ration NOTICE ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown 3 Fill Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the...

Page 185: ...ely 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 26 a ...

Page 186: ... 2 Disconnect 5 Throttle grip 1 6 Front brake master cylinder holder 1 7 Front brake master cylinder 1 8 Handlebar pinch bolt 1 Loosen 9 Handlebar bolt 1 10 Handlebar right 1 11 Handlebar weight 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R LS LS LS 1 5 2 ...

Page 187: ...cable 1 Disconnect 7 Clutch lever holder 1 8 Clutch switch 1 9 Handlebar pinch bolt 1 Loosen 10 Handlebar bolt 1 11 Handlebar left 1 12 Handlebar weight 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R New LT LS LS 9 6 7 5 2 8 11 ...

Page 188: ...usly weaken it EAS30205 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar weights 1 to the handlebars 2 TIP Fit the projection a on each handlebar weight into the hole b in the handlebar 3 Install Clutch switch Clutch lever holder 1 Clutch lever TIP Align the projection a ...

Page 189: ...s rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP Align the projection a on the grip end with the slot b in the handlebar weight While holding the grip end tighten the grip end bolt There should be 2 5 mm 0 08 0 20 in of clearance c between the handlebar grip and the grip end 7 Install Front brake master cylinder 1 Fr...

Page 190: ...ottle grip and then install the cables Align the projection a on the right handlebar switch with the hole b on the right handlebar First tighten the front screw then tighten the rear screw 9 Install Grip end right 1 TIP Align the projection a on the grip end with the slot b in the handlebar weight While holding the grip end tighten the grip end bolt There should be 1 5 mm 0 04 0 20 in of clearance...

Page 191: ... Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 12 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 26 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 192: ...FRONT WHEEL on page 4 18 1 Front fender 1 2 Front fender bracket 2 3 Front fork cap bolt 1 Loosen 4 Handlebar pinch bolt 1 Loosen 5 Upper bracket pinch bolt 1 Loosen 6 Lower bracket pinch bolt 1 Loosen 7 Front fork leg 1 1 3 7 2 2 6 4 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m k...

Page 193: ...s to both of the front fork legs 1 Protector 1 2 Front fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 30 Nm 3 0 m kgf 22 ft Ibf T R LT New New New New New New New 2 3 4 5 6 12 11 13 18 20 19 10 9 7 8 15 16 17 1 14 21 ...

Page 194: ...rod 1 12 Damper rod ring 1 13 Rebound spring 1 14 Inner tube 1 15 Oil seal 1 16 Washer 1 17 Outer tube bushing 1 18 Inner tube bushing 1 19 Oil flow stopper 1 20 Spring 1 21 Outer tube 1 30 Nm 3 0 m kgf 22 ft Ibf T R LT New New New New New New New 2 3 4 5 6 12 11 13 18 20 19 10 9 7 8 15 16 17 1 14 21 ...

Page 195: ...ack et pinch bolts support the front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the outer tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Front fork damper rod bolt 1 Copper washer...

Page 196: ...h a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA20550 When disassembling and assembling the front fork leg do not allow any foreign mate rial to enter the front fork EAS30209 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs...

Page 197: ...y down the in ner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube d Install the oil flow stopper and inner tube bushing onto the inner tube 6 2 Lubricate Inner tube s outer surface 3 Install Inner tube in the outer tube 4 Install Copper washer Front fork damper rod bolt 5 Tighten Front fork damper rod bolt 1 TIP While holding the damper rod assembl...

Page 198: ...just the oil seal clip so that it fits into the outer tube s groove 9 Fill Front fork leg with the specified amount of the recom mended fork oil 10 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachmen...

Page 199: ...stall Front fork leg 1 Temporarily tighten the lower bracket pinch bolt TIP Make sure the inner tube end is flush with the top of the handlebar 2 Tighten Lower bracket pinch bolt Upper bracket pinch bolt Handlebar pinch bolt Front fork cap bolt 3 Install Front fender bracket 1 Front fender TIP Align the edge a of each front fender bracket with the stopper b on the front fork 2 Make sure to fit the...

Page 200: ...FRONT FORK 4 69 2 b a 1 ...

Page 201: ...connector 2 Disconnect 2 Horn 1 3 Brake hose joint 1 4 Front brake hose guide 1 5 Horn bracket 1 6 Cable guide left 1 7 Cable guide right 1 8 Main switch coupler 1 Disconnect 9 Cap bolt 1 10 Upper bracket 1 11 Lock washer 1 12 Upper ring nut 1 3 2 4 1 5 6 9 10 11 12 13 14 16 17 15 18 19 7 8 1st 48 Nm 4 8 m kgf 35 ft Ibf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf...

Page 202: ...al 1 Removing the upper bracket and lower bracket Order Job Parts to remove Q ty Remarks 3 2 4 1 5 6 9 10 11 12 13 14 16 17 15 18 19 7 8 1st 48 Nm 4 8 m kgf 35 ft Ibf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R LS LS LS ...

Page 203: ...arings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set...

Page 204: ... of the guide contacts the upper bracket 3 tighten the cable guide bolt While holding the cable guide left so that the projection b on the guide contacts the upper bracket 3 tighten the cable guide bolt Make sure that the leads are routed properly through the guide Refer to CABLE ROUT ING on page 2 35 Recommended lubricant Lithium soap based grease T R Cable guide bolt right 7 Nm 0 7 m kgf 5 1 ft ...

Page 205: ...EAR BRAKE on page 4 42 1 Mudguard 1 2 Rear shock absorber assembly nut bolt lower side 1 1 3 Rear shock absorber assembly nut bolt upper side 1 1 4 Rear shock absorber assembly 1 5 Spacer 1 6 Drive chain guard 1 7 Pivot shaft cap 2 8 Pivot shaft nut 1 9 Pivot shaft 1 10 Swingarm 1 11 Drive chain guide 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R 115 ...

Page 206: ...he swingarm and rear shock absorber assembly Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R 115 Nm 11 5 m kgf 83 ft lbf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R LS LS LS LS LT 12 13 14 11 10 12 14 4 2 5 2 3 9 1 7 3 8 7 6 ...

Page 207: ... over TIP Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Measure Swingarm side play Swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Check the swingarm side play A by moving the swingarm from side to side If the swingarm has side to side play check the spacer bearings and dust covers c Check the swingarm vertical movement B by moving t...

Page 208: ...SHOCK ABSORBER ASSEMBLY 1 Install Spacer 1 Rear shock absorber assembly 2 To ensure that the seal lip a is positioned correctly install the spacer into the rear shock absorber assembly as follows a Push the spacer into the rear shock absorber assembly past the seal as shown in illustra tion A b Push the spacer in the opposite direction to the proper installation position as shown in il lustration ...

Page 209: ...SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY 4 78 2 1 1 1 a A B ...

Page 210: ...t Refer to GENERAL CHASSIS 3 on page 4 5 Coolant reservoir Refer to RADIATOR on page 6 1 Swingarm Refer to SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY on page 4 74 1 Drive sprocket cover 1 2 Drive chain guide 1 3 Drive chain 1 4 Drive sprocket nut 1 5 Washer 1 6 Drive sprocket 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 4 5 1 2 3 6 ...

Page 211: ...suring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry i...

Page 212: ...EAS30232 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 27 EAS30233 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 27 EAS31116 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Washer Drive sprocket nut TIP Install the drive sprocket with the mark a fac ing outward Before installing the drive sprocke...

Page 213: ...he drive sprocket cover Refer to CABLE ROUTING on page 2 35 2 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack...

Page 214: ...CHAIN DRIVE 4 83 ...

Page 215: ...IDE EXHAUST SIDE 5 24 CHECKING THE CYLINDER HEAD 5 24 INSTALLING THE CYLINDER HEAD 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 27 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 CHECKING THE VALVE LIFTERS 5 31 INSTALLING THE VALVES 5 31 CYLINDER AND PISTONS 5 34 REMOVING THE PISTONS 5 35 CHECKING THE CYLINDERS AND PISTONS 5 35 CH...

Page 216: ...LUTCH 5 54 SHIFT SHAFT 5 57 CHECKING THE SHIFT SHAFT 5 60 CHECKING THE STOPPER LEVER 5 60 INSTALLING THE SHIFT SHAFT 5 60 INSTALLING THE SHIFT ROD 5 60 OIL PUMP 5 62 CHECKING THE OIL PUMP IDLE GEAR 5 64 CHECKING THE OIL PUMP 5 64 CHECKING THE RELIEF VALVE 5 64 ASSEMBLING THE OIL PUMP 5 64 INSTALLING THE OIL PUMP 5 65 OIL PAN 5 66 CHECKING THE OIL STRAINER 5 67 INSTALLING THE OIL PAN 5 67 CRANKCASE...

Page 217: ...SHAFT ASSEMBLY 5 78 CHECKING THE CRANKSHAFT 5 80 CHECKING THE CONNECTING RODS 5 81 INSTALLING THE CONNECTING RODS 5 83 INSTALLING THE CRANKSHAFT 5 84 INSTALLING THE BALANCER SHAFT ASSEMBLY 5 85 TRANSMISSION 5 86 CHECKING THE SHIFT FORKS 5 90 CHECKING THE SHIFT DRUM ASSEMBLY 5 90 CHECKING THE TRANSMISSION 5 90 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 91 INSTALLING THE TRANSMISSION 5 91 ...

Page 218: ...ug wells to prevent it from falling into the cylinders 6 Install Extension 1 Compression gauge 2 7 Measure Compression pressure Out of specification Refer to steps c and d a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine TIP Th...

Page 219: ...e 4 5 Side panels Refer to GENERAL CHASSIS 2 on page 4 3 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Pistons valves cylinder head gasket or piston ring s possibly defec tive Repair T R Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 220: ...pler 1 Disconnect 2 Exhaust pipe protector 1 3 Exhaust pipe joint bolt 1 Loosen 4 Muffler assembly 1 5 Exhaust pipe joint 1 6 Gasket 1 7 Muffler protector outer 1 8 Muffler protector inner 1 9 Muffler 1 10 Exhaust pipe protector bracket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 20 Nm 2 0 ...

Page 221: ...er Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R New New 4 LT LT LT LT LT 1 2 4 5 6 11 13 12 10 3 9 8 7 ...

Page 222: ... AIR INDUCTION SYSTEM on page 7 15 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Coolant reservoir Refer to RADIATOR on page 6 1 Water pump inlet hose Refer to WATER PUMP on page 6 6 Radiator inlet hose Refer to THERMOSTAT on page 6 4 Drive chain Refer to CHAIN DRIVE on page 4 79 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 1 Negative battery lead 1 Disconnect 2 Spark ...

Page 223: ...ead 1 Disconnect 8 Engine ground lead 1 Disconnect 9 Coolant temperature sensor coupler 1 Disconnect 10 Oil pressure switch connector 1 Disconnect 11 Clutch cable 1 Disconnect Disconnecting the leads and cable Order Job Parts to remove Q ty Remarks 2 8 3 4 11 10 5 6 9 7 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 224: ...gine bracket right 1 8 Engine mounting bolt left front side 1 9 Engine mounting bolt right front side 1 10 Bushing 2 11 Engine mounting bolt nut rear lower side 1 1 12 Sidestand bolt 2 13 Sidestand 1 14 Engine mounting bolt nut rear upper side 1 1 15 Engine 1 16 Plate 2 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 66 Nm 6 6...

Page 225: ...s 2 Tighten Engine mounting nut rear upper side 4 Sidestand bolts 6 Engine mounting nut rear lower side 8 Engine mounting bolt right front side 10 Engine mounting bolt left front side 11 Engine bracket bolts right 13 Engine bracket bolts left 15 Engine mounting bolt right upper side 16 Engine mounting bolt left upper side 17 3 Install Engine mounting bolt caps 18 TIP Align the projection a on the ...

Page 226: ...Install Exhaust pipe protector bracket 5 to the exhaust pipe 5 Install Muffler assembly 6 Muffler assembly bolt 7 TIP Temporarily tighten the muffler assembly bolt 6 Tighten Muffler assembly bolt 7 Exhaust pipe joint bolt 8 7 Install Exhaust pipe protector 9 Installed depth a 3 3 5 mm 0 12 0 14 in 4 10 9 18 13 16 1 7 12 2 8 9 11 18 15 3 14 17 6 5 1 New 1 a New New T R Exhaust pipe nut 15 Nm 1 5 m ...

Page 227: ...ENGINE REMOVAL 5 10 T R Exhaust pipe protector bolt 8 Nm 0 8 m kgf 5 8 ft lbf LOCTITE 9 8 4 7 6 1 5 3 2 ...

Page 228: ...NERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Air cut off valve Reed valve Refer to AIR INDUCTION SYSTEM on page 7 15 Water pump housing Refer to WATER PUMP on page 6 6 Clutch cover Refer to CLUTCH on page 5 49 1 Spark plug cap 2 Disconnect 2 Spark plug 2 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide upper side 1 5 4 3 2 2 1 1 10 Nm 1 0 m kgf 7 ...

Page 229: ...t cap 1 7 Dowel pin 4 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 4 3 2 1 10 9 6 11 7 7 8 5 7 7 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 5 m kgf 11 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R E LS New New New New E 10 Nm ...

Page 230: ...een the projections d on the timing chain guide lower side 2 TIP When the alignment mark e on the intake cam shaft sprocket and the alignment mark f on the exhaust camshaft sprocket are aligned with the edge g of the cylinder head piston 1 is at 90 ATDC 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket a Insert the hexagon wrench 2 part No 1WS 12228 00 into the timing chain tension e...

Page 231: ... place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 2 1 2 1 3 2 1 2 1 Camshaft lobe dimensions Lobe height Intake 32 050 32 150 mm 1 2618 1 2657 in Limit 31 950 mm 1 2579 in Base circle diameter Intake 24 972 25 072 m...

Page 232: ... clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and camshaft caps as a set EAS30936 CHECKING THE CAMSHAFT SPROCKETS 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and timing ch...

Page 233: ...here is rough move ment replace the timing chain tensioner EAS30269 INSTALLING THE CAMSHAFTS 1 Align Marks a on the generator rotor with the slots b in the generator rotor cover Punch mark c on the balancer drive gear with the projections d on the timing chain guide lower side a Turn the crankshaft counterclockwise b Position the marks a on the generator rotor on both sides of the slots b in the g...

Page 234: ...n in the il lustration a Install the timing chain onto the exhaust cam shaft sprocket and then install the exhaust camshaft onto the cylinder head TIP Align the alignment mark b on the exhaust camshaft sprocket with the edge c of the cylin der head as shown in the illustration b Install the timing chain onto the intake cam shaft sprocket and then install the intake camshaft onto the cylinder head ...

Page 235: ...kshaft when installing the camshaft to avoid damage or improper valve timing TIP Tighten the camshaft cap bolts in the tightening sequence as shown 6 Install Timing chain tensioner gasket Timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the timing chain ten sioner rod fully counterclockwise with a hexagon wrench 1 Part No 1WS 12228 00 b Install a new tim...

Page 236: ...enera tor rotor cover Mark c Make sure that the punch mark c on the bal ancer drive gear 1 is positioned between the projections d on the timing chain guide lower side 2 Camshaft sprocket match mark e Make sure the match marks e on the cam shaft sprockets are aligned with the cylinder head mating surface f Out of alignment Adjust Refer to the installation steps above Timing chain guide Make sure t...

Page 237: ...4 INSTALLING THE CYLINDER HEAD COVER 1 Install Cylinder head cover gasket 1 to the cylinder head cover 2 TIP After installing the cylinder head cover gasket to the cylinder head cover cut off the a section 1 2 New 1 a 2 New ...

Page 238: ...o RADIATOR on page 6 1 Footrest assembly right Refer to REAR BRAKE on page 4 42 Muffler assembly exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Air cut off valve Reed valve Refer to AIR INDUCTION SYSTEM on page 7 15 Water pump housing Refer to WATER PUMP on page 6 6 Clutch cover Refer to CLUTCH on page 5 49 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R...

Page 239: ...1 12 Bushing 2 13 Timing chain bolt right side of cylinder head 1 14 Engine oil check bolt 1 Removing the cylinder head Following the tightening order loosen the bolt one by one and then retighten it to the specific torque Order Job Parts to remove Q ty Remarks 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7...

Page 240: ...Q ty Remarks 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 1st 3rd 2nd T R 12 Nm 1 2 m kgf 8 7 ft Ibf Specified angle 115 125 30 Nm 3 0 m kgf 22 ft Ibf 10 Nm 1 0 m kgf 7 2 f...

Page 241: ...ats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the sur...

Page 242: ...and then retighten it to the specific torque NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle TIP Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 3 stag es 4 Install Timing chain bolt right side of cylinder head 1 TIP Make sure that the timing chain bolt passes through the timing chain 2 T R Cylinder head bolt 1 6 1st 10 N...

Page 243: ...move Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 E E M M M New New New New M M 1 1 2 3 3 9 10 6 7 10 3 2 3 8 9 4 5 5 4 8 ...

Page 244: ...n solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Ide...

Page 245: ...2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit ...

Page 246: ...ting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b 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 TIP Where the valve seat and valve face contacted one another the bluein...

Page 247: ... forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b 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 ...

Page 248: ... of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem end with the recommended lubricant 3 Lubricate Valve stem seal 2 with the recommended lubricant Installed compression spring force intake 159 60 183 60 N 16 27 18 72 kgf 35 88 41 27 lbf Installed compression spring force exhaust 159 60 183 60 N 16 27 18 72 kgf 35 88 41 27 lbf Install...

Page 249: ...ve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve pad Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter b Smaller pitch M E 2 1 New 3 1 4 5 2 New Valve spring compressor 90890 04019 Valve s...

Page 250: ...VALVES AND VALVE SPRINGS 5 33 TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in their original position ...

Page 251: ...and pistons Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Cylinder 1 2 Cylinder gasket 1 3 Dowel pin 2 4 Piston pin clip 4 5 Piston pin 2 6 Piston 2 7 Top ring 2 8 2nd ring 2 9 Oil ring 2 E E New New New New E LS 1 3 3 6 5 4 4 2 7 8 9 ...

Page 252: ...moving a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to both of the cylinders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a...

Page 253: ...g the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace...

Page 254: ...e following procedure applies to both of the pistons 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 Piston ring Top ring End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 40 mm 0 0157 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 60 mm 0 0236 in Oil ring End gap installed 0 10 0 35 mm 0 0039 0 0138 in a 40 0 mm 1 57 in Pi...

Page 255: ... sure that the clip ends b are pistoned away from the cutout c in the piston as shown in the illus tration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 2 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins O ring Cylinder gasket 6 Install Cylinder 1 TIP While compressing the pisto...

Page 256: ...CYLINDER AND PISTONS 5 39 1 ...

Page 257: ...IL on page 3 22 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Crankshaft end cover 1 4 Timing mark accessing bolt 1 5 Generator cover 1 6 Generator cover gasket 1 7 Dowel pin 2 8 Stator coil assembly Stator coil Crankshaft po sition sensor 1 9 Starter clutch idle gear shaft 1 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 ...

Page 258: ...1 Removing the stator coil generator rotor and starter clutch Order Job Parts to remove Q ty Remarks 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R LT LT LT LT LT LT LT New New New E E E E M LS LT 3 3 9 1 2 3 4 5 10 14 12 15 13 11 9 6 7 7 8 ...

Page 259: ...CH 1 Remove Starter clutch bolts 1 Generator rotor 2 Starter clutch 3 TIP While holding the generator rotor with the rotor holding tool 4 loosen the starter clutch bolts When removing the starter clutch from the gen erator rotor make sure that the rollers 5 and starter clutch inner race 6 in the starter clutch remain in place EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch inner race 1...

Page 260: ...t should turn freely otherwise the starter clutch is faulty and must be re placed EAS30871 INSTALLING THE STARTER CLUTCH 1 Assemble Starter clutch rollers 1 Starter clutch inner race 2 to the starter clutch outer race 3 TIP When installing the starter clutch rollers and starter clutch inner race to the starter clutch out er race make sure that the springs a are point ing in the direction shown in ...

Page 261: ...ces with molybdenum dis ulfide grease 2 Tighten Generator rotor bolt 1 TIP While holding the generator rotor 2 with the ro tor holding tool 3 tighten the generator rotor bolt 3 Apply Sealant onto the stator coil lead grommet 4 Install Generator cover gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position ...

Page 262: ...to GENERAL CHASSIS 2 on page 4 3 Fuel tank cover assembly Front bottom cowling right Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 6 on page 4 16 1 Engine ground lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter motor 1 New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 2 1 3 ...

Page 263: ...Gasket 2 3 Starter motor yoke 1 4 Circlip 1 5 Armature assembly 1 6 Brush holder set 1 7 Brush 2 8 Brush holder 1 1 9 Spring 4 10 Brush holder 2 1 11 Starter motor rear cover 1 New LS LS New New New 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 4 1 3 2 2 11 6 7 7 10 8 9 4 5 ...

Page 264: ...nsulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brush or brush holder set 6 Measure Brush spring force Out of specification Replace the spring Diameter mm in Limit mm in Mica undercut de...

Page 265: ...ter motor yoke with the match marks b on the front cover and rear cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor lead terminal 2 Engine ground lead terminal 3 TIP Install the engine ground lead terminal so that the crimped section a of the terminal that se cures the ground leads is facing forward Brush spring force 6 08 9 12 N 620 930 gf 21 89 32 83 oz a b 2 1 ...

Page 266: ...fer to CHANGING THE ENGINE OIL on page 3 22 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Water pump housing Refer to WATER PUMP on page 6 6 1 Clutch cable 1 Disconnect 2 Clutch cable holder 1 3 Holder O2 sensor lead 2 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Circlip 1 E E LS LS New New New New New LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm ...

Page 267: ...Oil seal 1 13 Bearing 1 14 Bearing 1 Removing the clutch cover and pull lever shaft Order Job Parts to remove Q ty Remarks E E LS LS New New New New New LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 5 7 4 2 12 13 11 9 8 1 7 6 6 3 3 10 14 ...

Page 268: ...od 1 4 Bearing 1 5 Friction plate 1 2 6 Clutch plate 5 7 Friction plate 2 4 8 Clutch boss nut 1 9 Lock washer 1 10 Clutch boss 1 11 Thrust plate 1 12 Clutch housing 1 13 Spacer 1 14 Washer 1 New E E E E E LS E 9 8 4 4 3 4 6 5 2 1 6 6 6 5 7 6 7 7 7 14 13 11 10 12 10 Nm 1 0 m kgf 7 2 ft Ibf T R 100 Nm 10 m kgf 72 ft lbf T R ...

Page 269: ...s 2 4 Straighten the lock washer tab a 5 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut EAS30348 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replac...

Page 270: ...ings as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set EAS30352 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Oil pump drive gear 1 Cracks damage wear Replace the clutch h...

Page 271: ...e during operation Replace the crankshaft and clutch housing as a set EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS30358 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth...

Page 272: ... Pressure plate 2 Clutch springs 3 Clutch spring bolts 4 TIP Apply lithium soap based grease onto the pull rod Tighten the clutch spring bolts in stages and in a crisscross pattern 4 Install Bearings 1 Oil seal 2 to the clutch cover TIP Lubricate the bearings with engine oil and lubri cate the oil seal with lithium soap based grease Install the bearings until they contact the sur faces a and insta...

Page 273: ...tern After installing the clutch cover make sure that the alignment mark b on the clutch cover is aligned with the punch mark c on the pull le ver 7 6 Connect Clutch cable 1 TIP Install the clutch cable so that the clutch cable length a is 52 6 64 1 mm 2 07 2 52 in as shown in the illustration After installing the clutch cable bend the pro jection b on the pull lever 7 Adjust Clutch lever free pla...

Page 274: ...ob Parts to remove Q ty Remarks 1 Shift rod locknut shift arm side 1 2 Shift rod locknut shift pedal side 1 Left hand threads 3 Shift rod 1 4 Shift arm 1 5 Shift pedal 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R LS 4 1 2 5 3 ...

Page 275: ...efer to CHANGING THE ENGINE OIL on page 3 22 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Water pump housing Refer to WATER PUMP on page 6 6 Clutch housing Refer to CLUTCH on page 5 49 Shift arm Refer to SHIFT SHAFT on page 5 57 1 Shift shaft 1 2 Washer 1 3 Circlip 2 4 Shift shaft spring 1 5 Stopper lever spring 1 6 Shift shaft spring stopper 1 7 Stopper lever 1 New E LS E LT E 9 8 1 2...

Page 276: ...SHIFT SHAFT 5 59 8 Oil seal 1 9 Bearing 1 Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks New E LS E LT E 9 8 1 2 New 3 4 6 7 5 22 Nm 2 2 m kgf 16 ft Ibf T R ...

Page 277: ...e illustration 2 Install Stopper lever Collar Shift shaft spring stopper Stopper lever spring Shift shaft assembly TIP Hook the end of the shift shaft spring 1 onto the shift shaft spring stopper 2 Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the projection a on the lower crankcase Make sure that the base b of the hooked end of the stopper lever spring is positioned as ...

Page 278: ...ads b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position c Tighten both locknuts TIP The shift rod locknut shift pedal side has left hand threads Installed length a 141 6 145 6 mm 5 57 5 73 in Direction a Installed shift rod length increases Direction b Installed shift rod length decreases 1 b a a T R Shift rod locknut shift arm side 7 Nm 0 7 m kgf 5 1 ft lbf Shift...

Page 279: ...right Refer to GENERAL CHASSIS 3 on page 4 5 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Water pump housing Refer to WATER PUMP on page 6 6 Clutch housing Refer to CLUTCH on page 5 49 1 Circlip 1 2 Oil pump idle gear 1 3 Oil pump assembly 1 4 Dowel pin 2 M E E New 1 4 2 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 280: ...l pump cover 1 2 Pin 1 3 Oil pump driven gear 1 4 Oil pump rotor assembly 1 5 Oil pump inner rotor 1 6 Oil pump outer rotor 1 7 Circlip 1 Hold down the washer when removing the circlip 8 Washer 1 9 Spring 1 10 Relief valve 1 8 7 9 10 2 3 1 4 5 6 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R E New E ...

Page 281: ...t steps 1 and 2 or replace the defective part s EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve 1 Spring 2 Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the recommended lubricant 2 Lubricate Oil pump driven gear with the recommended lubricant 3 Install Inner rotor 1 Outer rotor 2 Oil pump driven gear 3 Pin 4 Oil pump co...

Page 282: ...ump operation Refer to CHECKING THE OIL PUMP on page 5 64 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 NOTICE ECA21870 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump cover screw 2 0 Nm 0 20 m kgf 1 4 ft lbf T R Oil pump bolt 10 Nm 1 0 m kgf 7 2 ft lbf 2 3 4 1 5 6 a 1 2 2 1 ...

Page 283: ...rvoir Refer to RADIATOR on page 6 1 Footrest assembly right Refer to REAR BRAKE on page 4 42 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 1 Engine oil drain bolt 1 2 Front bottom cowling bracket 1 3 Oil pan 1 4 Oil pan gasket 1 5 Oil strainer 1 6 Oil strainer seal 1 1 3 2 5 6 4 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 f...

Page 284: ...m cowling bracket 1 TIP Tighten the oil pan bolts in stages and in a crisscross pattern While holding the front bottom cowling bracket so that the projection a on the bracket con tacts the oil pan tighten the front bottom cowl ing bracket bolt 3 Install Gasket 1 Engine oil drain bolt 2 TIP Install the new gasket as shown in the illustra tion T R Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Front bottom...

Page 285: ... on page 5 40 Starter motor Refer to ELECTRIC STARTER on page 5 45 Water pump housing Refer to WATER PUMP on page 6 6 Clutch housing Refer to CLUTCH on page 5 49 Oil pump assembly Refer to OIL PUMP on page 5 62 Oil strainer Refer to OIL PAN on page 5 66 Drive sprocket Refer to CHAIN DRIVE on page 4 79 1 Gear position switch 1 2 Oil pressure switch 1 3 Oil filter cartridge 1 1 8 Nm 0 18 m kgf 1 3 f...

Page 286: ...er 1 8 Crankcase breather cover gasket 1 9 Speed sensor 1 Removing the crankcase breather cover and switches Order Job Parts to remove Q ty Remarks 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LS New New New LT LT LT E LS LT 2 7 5 7 6 9 8 1 3 4 ...

Page 287: ...chain guide intake side 1 7 Balancer drive gear 1 8 Upper crankcase 1 9 Dowel pin 2 10 Oil nozzle 1 11 Plug 2 2 2 3 3 1 5 3 6 4 7 8 9 10 11 11 2 6 2 9 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd 24 Nm 2 4 m kgf 17 ft Ibf T R 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd 26 Nm 2 6 m kgf 19 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 288: ...olt 21 TIP Loosen each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in the proper sequence as shown M6 35 mm bolt 2 1 2 M6 45 mm bolt 5 3 7 8 12 13 M6 65 mm bolt 3 bolts with copper washers 4 5 9 M6 65 mm bolt 3 6 10 11 M8 50 mm bolt 2 14 15 M8 80 mm bolt 6 16 21 4 Remove Upper crankcase Dowel pins Oil fi...

Page 289: ...d solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS30744 CHECKING THE OIL NOZZLES 1 Check Oil nozzle Damage wear Replace Oil passage Obstruction Blow out with compressed air EAS30397 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft journal bearing inner surface w...

Page 290: ...icate the bolts 1 15 and 17 21 threads and mating surfaces with engine oil Lubricate the mating surface of the bolt 16 with engine oil and apply Yamaha bond No 1215 to the bolt threads Finger tighten the crankcase bolts M8 80 mm bolt 6 1 6 M8 50 mm bolt 2 7 8 M6 45 mm bolt 5 9 10 14 15 19 M6 65 mm bolt 3 11 12 16 M6 65 mm bolt 3 bolts with copper washers 13 17 18 M6 35 mm bolt 2 20 21 7 Tighten Cr...

Page 291: ...ce as shown 9 Install Balancer drive gear 1 TIP Align the punch mark a in the balancer drive gear with the punch mark b in the balancer driven gear T R Crankcase bolts 1 6 1st 20 Nm 2 0 m kgf 14 ft lbf 2nd 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 7 8 1st 20 Nm 2 0 m kgf 14 ft lbf 2nd 26 Nm 2 6 m kgf 19 ft lbf T R Crankcase bolts 9 21 10 Nm 1 0 m kgf 7 2 ft lbf 2 6 8 5 4 1 2 6 3 7 A Lower crankcas...

Page 292: ...rive gear bolt 11 Install Holder O2 sensor lead gear position switch lead and crankshaft position sensor lead 1 Holder O2 sensor lead 2 TIP Position the holder 1 within the range shown in the illustration Make sure that the holder 2 contacts the pro jection a on the crankcase breather cover EAS31313 INSTALLING THE OIL PRESSURE SWITCH AND GEAR POSITION SWITCH 1 Install Oil pressure switch 1 Oil pre...

Page 293: ...g 1 Gear position switch 2 TIP Lubricate the O ring with lithium soap based grease While holding the gear position switch so that the flange a on the switch contacts the crank case tighten the gear position switch screws T R Gear position switch screw 3 5 Nm 0 35 m kgf 2 5 ft lbf LOCTITE 2 1 New 2 2 1 a a New ...

Page 294: ...aft assembly 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 3 6 Crankshaft journal upper bearing 3 7 Connecting rod cap 2 8 Big end lower bearing 2 9 Connecting rod 2 10 Big end upper bearing 2 11 Oil nozzle 1 1st 15 Nm 1 5 m kgf 11 ft lbf 2nd Specified angle 145 155 T R E E E E E E E E E E M M M M New New New N...

Page 295: ... gear Cracks damage wear Replace the balanc er drive gear and balancer shaft assembly as a set Excessive noise during operation Replace the balancer drive gear and balancer shaft assembly as a set 2 Measure Balancer shaft runout Out of specification Replace the balancer shaft assembly 3 Check Balancer shaft assembly Cracks damage wear Replace the balanc er shaft assembly and journal bearings Dirt ...

Page 296: ...tightening sequence Refer to ASSEMBLING THE CRANKCASE on page 5 72 f Remove the upper crankcase and the bal ancer shaft journal upper bearings g Measure the compressed Plastigauge width e on each balancer shaft journal If the balancer shaft journal to balancer shaft journal bearing clearance is out of specification select replacement balancer shaft journal bearings 5 Select Balancer shaft journal ...

Page 297: ...e and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Install the crankshaft journal lower bearings 1 and the crankshaft into the lower crank case TIP Align the projections a on the crankshaft jour nal lower bearings with the notches b in the low...

Page 298: ...ngs 4 Select Crankshaft journal bearings J1 J3 TIP The numbers A stamped into the crankcase and the numbers B stamped into the crank shaft web are used to determine the replace ment crankshaft journal bearing sizes J1 J3 refer to the bearings shown in the crank case and crankshaft web illustration If J1 J3 are the same use the same size for all of the bearings For example if the crankcase J1 and c...

Page 299: ...rement has been completed Lubricate the bolt threads and nut seats with molybdenum disulfide oil Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned Make sure that the projections e on the con necting rod cap faces the same direction as the Y mark c on the connecting ro...

Page 300: ...he big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the Y marks c on the connecting rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned Make sure that the projections e on the con necting rod cap faces ...

Page 301: ... rod bolt and nut with a new one and perform the procedure again NOTICE ECA19930 Do not use a torque wrench to tighten the connecting rod nut to the specified angle Tighten the nut until it is at the specified an gle TIP On a hexagonal nut note that the angle from one corner to another is 60 EAS31077 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings into the upper crankcase Cra...

Page 302: ...rings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each balancer shaft journal bearing in its original place A Upper crankcase B Lower crankcase a b 1 A 1 a b B ...

Page 303: ...7 1 Drive axle assembly 1 2 Clip 2 3 Oil seal 2 4 Bearing 1 5 Main axle assembly 1 6 Clip 1 7 Oil seal 1 8 Bearing 1 9 Shift fork guide bar retainer 1 1 10 Shift fork guide bar retainer 2 1 11 Shift fork guide bar 2 12 Spring 4 13 Shift fork L 1 14 Shift fork R 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New New LT E E E E E E LS LS LS E M M M E E E 2 7 8 6 4 1 3 3 14 1...

Page 304: ... shaft 1 Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New New LT E E E E E E LS LS LS E M M M E E E 2 7 8 6 4 1 3 3 14 13 5 2 15 11 11 12 12 17 12 12 9 10 16 ...

Page 305: ...e main axle assembly Order Job Parts to remove Q ty Remarks 1 2nd pinion gear 1 2 6th pinion gear 1 3 3rd pinion gear 1 4 Circlip 1 5 Washer 1 6 5th pinion gear 1 7 Circlip 1 8 Bearing 1 9 Main axle 1 1 3 4 9 8 7 5 6 2 E New New M M M M ...

Page 306: ...rks 1 Washer 1 2 1st wheel gear 1 3 Collar 1 4 Washer 1 5 5th wheel gear 1 6 Circlip 1 7 Washer 1 8 4th wheel gear 1 9 3rd wheel gear 1 10 6th wheel gear 1 11 Circlip 1 12 Washer 1 13 2nd wheel gear 1 14 Bearing 1 15 Drive axle 1 E M New New M M M M M M M M 1 3 4 5 7 6 2 8 10 11 12 13 9 15 14 ...

Page 307: ...ce the shift forks and shift fork guide bar as a set EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS30433 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and ...

Page 308: ... DRIVE AXLE 1 Install 2nd pinion gear 1 TIP Press the 2nd pinion gear onto the main axle un til the press fitting height a is 122 1 122 3 mm 4 80 4 81 in as shown in the illustration 2 Install Circlip 1 TIP Align the opening between the ends a of the circlip with a groove b in the axle EAS30438 INSTALLING THE TRANSMISSION 1 Install Oil pump idle gear shaft 1 TIP Install the oil pump idle gear shaf...

Page 309: ...ankcase and lower crankcase as shown in the illustration Make sure that the ends of the clips are posi tioned within the range shown in the illustra tion Install shift fork C 5 into the groove in the 3rd pinion gear on the main axle Install shift fork L 6 into the groove in the 6th wheel gear and shift fork R 7 into the groove in the 5th wheel gear on the drive axle 4 Check Transmission Rough move...

Page 310: ...TRANSMISSION 5 93 ...

Page 311: ...IATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 8 CHECKING THE WATER PUMP 6 8 ASSEMBLING THE WATER PUMP 6 8 INSTALLING THE CLUTCH COVER 6 9 ...

Page 312: ...ANGING THE COOLANT on page 3 24 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir breather hose 1 4 Coolant reservoir cover 1 5 Coolant reservoir 1 6 Coolant reservoir cap 1 7 Radiator fan motor coupler 1 Disconnect 8 Radiator outlet hose 1 9 Radiator inlet hose 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft I...

Page 313: ...moving the radiator Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 2 Nm 0 2 m kg 1 4 ft Ib T R 1 2 3 3 4 5 6 7 9 10 12 11 8 ...

Page 314: ...ure 4 Check Radiator fan Damage malfunction Replace Refer to COOLING SYSTEM on page 8 27 EAS30440 INSTALLING THE RADIATOR 1 Install Spring nuts 1 to the radiator TIP Install the spring nuts to the radiator with its pro jection a facing inward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or...

Page 315: ... assembly right Refer to GENERAL CHASSIS 3 on page 4 5 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Coolant reservoir Refer to RADIATOR on page 6 1 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Radiator inlet hose 1 Disconnect 4 Thermostat cover 1 5 Thermostat 1 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 17 Nm 1 7 m kgf 12 f...

Page 316: ...ce EAS30939 INSTALLING THE THERMOSTAT 1 Install Thermostat 1 to the thermostat cover Thermostat cover 2 TIP Align the breather hole a in the thermostat 1 with the tab b on the thermostat gasket 3 Align the slot c in the thermostat cover with the tab b on the thermostat gasket 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Ch...

Page 317: ...22 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 1 Clutch cable 1 Disconnect 2 Radiator outlet hose 1 3 Water pump housing 1 4 Water pump housing gasket 1 5 Clutch cable holder 1 6 Holder O2 sensor lead 2 7 Clutch cover 1 LS New New New New New LT LT LT LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm...

Page 318: ...eal assembly 1 Removing the water pump Order Job Parts to remove Q ty Remarks LS New New New New New LT LT LT LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 4 7 7 5 3 2 9 9 6 6 15 8 12 14 10 11 13 1 ...

Page 319: ...ied depth as shown in the illustration 2 Install Impeller shaft 1 Impeller shaft retaining plate 2 Washer 3 Pin 4 Water pump driven gear 5 Washer 6 Circlip 7 TIP After installing the impeller shaft inject a small amount of molybdenum disulfide oil into the hole a in the clutch cover After installation check that the impeller shaft rotates smoothly Install depth a 0 2 0 7 mm 0 01 0 03 mm Mechanical...

Page 320: ...ignment mark b on the clutch cover is aligned with the punch mark c on the pull le ver 7 2 Connect Clutch cable 1 TIP Install the clutch cable so that the clutch cable length a is 52 6 64 1 mm 2 07 2 52 in as shown in the illustration After installing the clutch cable bend the pro jection b on the pull lever 3 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12...

Page 321: ...om mended coolant Refer to CHANGING THE COOLANT on page 3 24 5 Check Cooling system Leaks Repair or replace the faulty part 6 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 ...

Page 322: ...WATER PUMP 6 11 ...

Page 323: ...CHECKING THE INJECTORS BEFORE REMOVING 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODIES 7 8 CHECKING THE THROTTLE BODIES AND ISC IDLE SPEED CONTROL VALVE 7 8 CHECKING THE THROTTLE BODY JOINT 7 11 INSTALLING THE FUEL INJECTORS 7 11 CHECKING THE INJECTOR PRESSURE 7 11 CHECKING THE FUEL PRESSURE 7 12 INSTALLING THE THROTTLE BODY JOINT 7 12 AIR INDUCTION SYSTEM 7 ...

Page 324: ...acket bolt frame 2 3 Fuel tank overflow hose 1 4 Fuel tank breather hose 1 5 Fuel pump coupler 1 Disconnect 6 Fuel hose 1 7 Fuel tank 1 8 Front fuel tank bracket bolt fuel tank 2 9 Front fuel tank bracket 1 10 Rear fuel tank bracket bolt fuel tank 2 11 Rear fuel tank bracket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 325: ...18 Fuel filter 1 19 Fuel pump 1 Removing the fuel tank and fuel pump Order Job Parts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R New New LT 3 4 9 1 8 8 1 11 2 7 6 6 13 15 17 19 18 16 12 14 10 10 5 ...

Page 326: ...efore removing the hose place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel ...

Page 327: ...lder 1 onto the portion e of the fuel pump EAS30456 INSTALLING THE FUEL PUMP 1 Install Fuel pump gasket 1 Fuel pump 2 Fuel pump bracket TIP Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket When installing the fuel pump gasket make sure that there is no foreign material between the gasket and the surrounding parts The gasket li...

Page 328: ...ly connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel rail and fuel pump until a distinct click is heard To install the fuel hose slide the fuel hose con nector cover 1 on each end of the hose in the direction of the arrow shown a c b 2 2 1 New 1 e d 4 6...

Page 329: ...NK on page 7 1 Air filter case Refer to GENERAL CHASSIS 6 on page 4 16 1 Throttle body sensor assembly coupler 1 Disconnect 2 ISC idle speed control valve coupler 1 Disconnect 3 Injector coupler 2 Disconnect 4 Throttle body joint clamp screw 2 Loosen 5 Throttle bodies 1 6 Throttle cable decelerator cable 1 Disconnect 7 Throttle cable accelerator cable 1 Disconnect 8 Throttle body joint 1 1 2 3 5 4...

Page 330: ...Order Job Parts to remove Q ty Remarks 1 ISC idle speed control valve plate 1 2 ISC idle speed control valve 1 3 Spring 1 4 Cap 2 5 Fuel rail 1 6 Fuel injector 2 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R New New New New New New 1 2 3 4 4 5 6 6 ...

Page 331: ...Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 94 EAS30479 CHECKING THE THROTTLE BODIES TIP Before checking the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joint Fuel hose Air induction system Exhaust system Crankcase breather hose WARNING EWA17850 If the throttle bodies are subjected to strong shocks or dropped during...

Page 332: ... body in a downward direction from the air filter case side of the throttle body to the engine side NOTICE ECA18470 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not allow carbon deposits or other for eign materials to enter any of the passages in each throttle body or in the space be tween the throttle valve sha...

Page 333: ... the ISC valve and the ISC valve installation hole b in the throttle bodies 3 Install Spring O ring 1 ISC idle speed control valve 2 ISC idle speed control valve plate 3 NOTICE ECA21861 Do not use the ISC valve if it was dropped Do not allow water to enter the ISC valve and do not allow foreign materials to ad here to the assembly Do not touch the terminals of the coupler directly Because the forc...

Page 334: ...the injector pressure after the fuel in jectors are installed to the throttle bodies Refer to CHECKING THE INJECTOR PRESSURE on page 7 11 EAS30481 CHECKING THE INJECTOR PRESSURE TIP After installing the fuel injectors perform the following steps to check the injector pressure Do not allow any foreign materials to enter the fuel lines 1 Check Injector pressure a Connect the fuel injector pressure a...

Page 335: ... hose by hand Do not forcefully disconnect the hose with tools c Connect the pressure gauge 3 and adapter 4 to the fuel hose 2 d Start the engine e Measure the fuel pressure Faulty Replace the fuel pump 2 Install Fuel tank Refer to FUEL TANK on page 7 1 EAS30937 INSTALLING THE THROTTLE BODY JOINT 1 Install Throttle body joint 1 TIP Align the projection a on the throttle body joint with the slot b ...

Page 336: ...THROTTLE BODIES 7 13 c 1 cylinder d 2 cylinder A Left B Right b a d c A B b 1 ...

Page 337: ...THROTTLE BODIES 7 14 ...

Page 338: ...AIR INDUCTION SYSTEM 7 15 EAS20071 AIR INDUCTION SYSTEM 1 2 3 4 5 1 2 ...

Page 339: ...UCTION SYSTEM 7 16 1 Air induction system hose Air filter case to air cut off valve 2 Air cut off valve 3 Air induction system hose air cut off valve to reed valve cover 4 Reed valve assembly 5 Air filter case ...

Page 340: ...Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 1 Air induction system solenoid coupler 1 Disconnect 2 Air cut off valve 1 3 Air induction system hose air filter case to air cut off valve 1 4 Air induction system hose air cut off valve to reed valve cover 1 5 Reed valve cover 1 6 Reed valve assembly 1 7 Reed valve plate 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m...

Page 341: ... the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace...

Page 342: ...AIR INDUCTION SYSTEM 7 19 ...

Page 343: ...ROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 33 YAMAHA DIAGNOSTIC TOOL 8 34 TROUBLESHOOTING DETAILS 8 37 FUEL PUMP SYSTEM 8 69 CI...

Page 344: ...CAPS 8 88 CHECKING THE IGNITION COILS 8 88 CHECKING THE IGNITION SPARK GAP 8 89 CHECKING THE CRANKSHAFT POSITION SENSOR 8 89 CHECKING THE LEAN ANGLE SENSOR 8 89 CHECKING THE STARTER MOTOR OPERATION 8 90 CHECKING THE STATOR COIL 8 90 CHECKING THE RECTIFIER REGULATOR 8 91 CHECKING THE FUEL SENDER 8 91 CHECKING THE FUEL METER 8 92 CHECKING THE SPEED SENSOR 8 92 CHECKING THE RADIATOR FAN MOTOR 8 92 CH...

Page 345: ......

Page 346: ...R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L B...

Page 347: ...osition sensor 11 Battery 12 Engine ground 13 Main fuse 17 Diode 3 27 Lean angle sensor 29 ECU engine control unit 30 Ignition coil 1 31 Spark plug 32 Ignition coil 2 51 Gear position switch 67 Handlebar switch right 70 Engine stop switch A Wire harness B Negative battery sub wire harness ...

Page 348: ... Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 89 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 88 Replace the spark plug cap s 6 Check the igniti...

Page 349: ... Replace the right handlebar switch 10 Check the diodes Diode 1 and 3 Refer to CHECKING THE DI ODES on page 8 86 Replace the diode s 11 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 89 Replace the lean angle sensor 12 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wiring har ness Replace the ECU Refer to ...

Page 350: ... Y B R W R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R G...

Page 351: ...ain fuse 14 Starter relay 15 Starter motor 16 Diode 2 17 Diode 3 18 Starting circuit cut off relay 19 Diode 4 29 ECU engine control unit 51 Gear position switch 53 Handlebar switch left 58 Clutch switch 67 Handlebar switch right 69 Start switch 70 Engine stop switch A Wire harness B Negative battery sub wire harness ...

Page 352: ...om operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 14 1 13 4 15 a 11 8 10 9 7 6 2 3 12 5 b a WHEN THE TRANSMISSION IS IN NEUTRAL b...

Page 353: ...he battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 90 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 47 Repair or replace the starter motor 5 Check the starting circuit cut off re lay R...

Page 354: ... SWITCHES on page 8 77 Replace the clutch switch 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 77 The engine stop switch is faulty Replace the right handlebar switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 77 The start switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page...

Page 355: ...ELECTRIC STARTING SYSTEM 8 10 ...

Page 356: ...R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L B...

Page 357: ...CHARGING SYSTEM 8 12 8 AC magneto 10 Rectifier regulator 11 Battery 12 Engine ground 13 Main fuse A Wire harness B Negative battery sub wire harness ...

Page 358: ... to CHECKING AND CHARGING THE BATTERY on page 8 82 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 90 Replace the stator coil assembly Stator coil Crankshaft position sensor 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 91 Replace the rectifier regulator 5 Check the entire chargin...

Page 359: ...CHARGING SYSTEM 8 14 ...

Page 360: ...R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L B...

Page 361: ...ngine control unit 39 Meter assembly 47 High beam indicator light 49 Meter light 53 Handlebar switch left 54 Pass switch 55 Dimmer switch 64 Headlight right 65 Headlight left 66 Auxiliary light 72 Tail brake light 73 License plate light 74 Tail brake light License plate light connector 75 Headlight relay A Wire harness B Negative battery sub wire harness ...

Page 362: ...B SOCKETS on page 8 79 Replace the bulb s and bulb socket s 2 Check the fuses Ignition signaling system backup headlight and main Refer to CHECKING THE FUS ES on page 8 81 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 82 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 77 Repla...

Page 363: ...E LAYS on page 8 85 Replace the headlight relay 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or replace the wiring har ness Replace the ECU meter assembly or tail brake light Refer to REPLACING THE ECU engine control unit on page 8 81 ...

Page 364: ... R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L ...

Page 365: ...unction meter 1 45 Shift timing indicator light 46 Multi function meter 2 48 Turn signal indicator light 50 Oil pressure switch 51 Gear position switch 52 Turn signal relay 53 Handlebar switch left 56 Horn switch 57 Horn 59 Turn signal switch 60 Rear turn signal light left 61 Rear turn signal light right 62 Front turn signal light left 63 Front turn signal light right 67 Handlebar switch right 68 ...

Page 366: ...he fuses Ignition signaling system backup and main Refer to CHECKING THE FUS ES on page 8 81 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 82 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 77 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT ...

Page 367: ... Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the tail brake light 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 79 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING ...

Page 368: ...replace the wiring har ness Replace the meter assembly 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness 2 Disconnect the oil pressure switch lead from the oil pressure switch and then check whether the oil pressure warning light comes on when the lead is connected to the engine ground Replace the meter assembly Replace...

Page 369: ...har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 92 Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 8...

Page 370: ... 8 81 1 Check that the shift timing indicator light is set to come on and that the brightness level of the light is ad justed properly Refer to MULTI FUNCTION METER UNIT on page 1 4 Replace the meter assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system s wiring Replace the meter assembly ...

Page 371: ...SIGNALING SYSTEM 8 26 ...

Page 372: ... W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L B ...

Page 373: ...n fuse 5 Backup fuse 7 Radiator fan motor fuse 11 Battery 12 Engine ground 13 Main fuse 29 ECU engine control unit 37 Coolant temperature sensor 76 Radiator fan motor relay 77 Radiator fan motor A Wire harness B Negative battery sub wire harness ...

Page 374: ...e s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 82 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 77 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 92 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECK...

Page 375: ... 8 30 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 81 ...

Page 376: ...B R W R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G...

Page 377: ...or 27 Lean angle sensor 28 Speed sensor 29 ECU engine control unit 30 Ignition coil 1 31 Spark plug 32 Ignition coil 2 33 Fuel injector 1 34 Fuel injector 2 35 Air induction system solenoid 36 ISC idle speed control valve 37 Coolant temperature sensor 38 Yamaha diagnostic tool coupler 39 Meter assembly 43 Multi function meter 1 44 Engine trouble warning light 51 Gear position switch 53 Handlebar s...

Page 378: ...e trouble warning light comes on for around 2 seconds after the main switch has been set to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sen sor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nat...

Page 379: ...wing sensors and actuators in the diagnostic mode Refer to TROU BLESHOOTING DETAILS on page 8 37 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions For i...

Page 380: ...agnostic tool Malfunction mode Malfunction results are displayed in the top part of the window area Fault diagnosis mode Fault codes recorded on the ECU are read and the contents are dis played The freeze frame data FFD is the operation data when a malfunction was detected This data can be used to identify when the malfunction occurred and check the engine conditions and running conditions when it...

Page 381: ...list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 5 Item The item names of the detected malfunction are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 382: ... the probable cause of the malfunction following the order given After the check and service of the malfunctioning part have been completed reset the meter display according to the reinstatement method Fault code No Fault code number displayed on the meter when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF...

Page 383: ...nstalled condition of crankshaft position sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Refer to GENERATOR AND STARTER CLUTCH on page 5 40 Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECK...

Page 384: ...white blue blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for looseness or pinch ing Check for looseness or pinch ing Improperly installed sensor Replace the throttle bodies Refer to THROTTLE BODIES on page 7 6 Turn the main switch to ON Fault code numbe...

Page 385: ...tached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure Procedure Set the engine stop switch to and then operate the throttle while pushing the start switch If the display value changes the perfor mance is OK Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Conditi...

Page 386: ...e No 14 Item Intake air pressure sensor hose system malfunction clogged or de tached hose Fault code No 15 Item Throttle position sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Tool display Throttle position sensor signal 14 20 fully closed position 97 107 fully open position Procedure Check with throttle valves fully closed ...

Page 387: ...or Replace the throttle bodies Refer to THROTTLE BODIES on page 7 6 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valves are ful ly closed A value of 14 20 is indicated When throttle val...

Page 388: ...ttle valves Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 81 Fault code No 16 Item Throttle position sensor stuck throttle position sensor is detected signal from throttle position sensor will not change Fault code No 19 Item Black red lead of the ECU ...

Page 389: ...Item Coolant temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 06 Tool display When engine is cold Displays temperature closer to air temperature When engine is hot Displays current coolant temperature Procedure Compare the actually measured coolant temperature with the meter dis play value Item Probable cause of malfun...

Page 390: ...ode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the coolant tem perature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 92 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to...

Page 391: ...N Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for looseness or pinch ing Check for looseness or pinch ing Improperly installed sensor Replace the throttle bodies Refer to THROTTLE BODIES on page 7 6 Turn the main switch to ON Fault code number is not dis played Service is finished F...

Page 392: ... the diagnostic mode Code No 63 Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between O2 sensor coupler and ECU coupler gray green gray green pink black pink black black blue black blue Between O2 sensor coupler and starter relay coupler red white red white Between starter...

Page 393: ...finished Fault code number is displayed Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 Upright 0 4 1 4 V Overturn 3 7 4 4 V Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 89 Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Malfun...

Page 394: ...or approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of cylinder 1 ignition coil Check for looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finishe...

Page 395: ...lt code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between cylinder 2 ignition coil connector and ECU coupler gray red gray red Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to...

Page 396: ...fy the malfunctioning fuel injector Execute the diagnostic mode Code Nos 36 37 Identify the fuel injector that does not produce an operating sound Perform the following proce dures for the defective fuel injec tor 2 Connection of fuel injector 1 and or fuel injector 2 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking c...

Page 397: ... Tool display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 45 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of lean angle sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken ter...

Page 398: ...rmal signals are received from the speed sensor B Gear position switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 07 Tool display Speed sensor pulse 0 999 Procedure Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each tim...

Page 399: ...ness Between speed sensor coupler and ECU coupler blue blue black blue black blue white yellow white yellow Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value increases Go to item A 7 and delete the fault code Value does not increase Go to item A 5 A 5 Defective speed sensor Check the speed sensor Replace if defective Refer to C...

Page 400: ...n Go to item B 2 When the transmission is in gear with the clutch lever squeezed ON Incorrect indication Go to item C 2 for the clutch switch B 2 Connection of gear position switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the ...

Page 401: ... Go to item B 6 B 6 Defective gear position switch Check the gear position switch Replace if defective Refer to CHECKING THE GEAR POSITION SWITCH on page 8 93 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item B 9 and delete the fault code Incorrect indication Go to item B ...

Page 402: ...ith the transmission in gear Procedure Operate the transmission and clutch lever Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion C 1 Locate the malfunction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value does not increase Go to item A 2 for the speed sen sor Execute the diagno...

Page 403: ...nect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 21 When the clutch lever is re leased with the transmission in gear OFF When the clutch lever is squeezed with the transmission in gear ON Correct indication Go to item C 9 and delete the f...

Page 404: ...lt code num ber is not displayed Fault code No 42 Item A Speed sensor no normal signals are received from the speed sensor B Gear position switch open or short circuit is detected C Clutch switch open or short circuit is detected Fault code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector and fuel pump Fail safe system Able to start engine Able to drive vehicle Diagno...

Page 405: ...Between radiator fan motor re lay coupler and ignition fuse red white red white Between ignition fuse and main switch coupler brown red brown red Between main switch coupler and starter relay coupler red red Between starter relay coupler and battery red red Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is disp...

Page 406: ...d Fault code number is displayed Repeat item 1 If the same number is indicated go to item 5 3 02 is indicated in diagnostic mode code No 60 EEP ROM data error for adjustment of CO concentration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EE PROM Refer to ADJUSTING THE EX HAUST GAS VOLUME on page 3 11 After this adjustment is made turn the main switch to OFF Turn the main...

Page 407: ... malfunction is detected in the ECU the fault code number might not appear on the meter display Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 81 Tur...

Page 408: ...ool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code number is not dis played Service is finished Fault cod...

Page 409: ...ha diagnostic tool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Connect the Yamaha diagnostic tool and turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective Yamaha diagnostic tool Replace the Yamaha diagnostic tool Connect the Yamaha dia...

Page 410: ... the wire harness Between ECU coupler and Yamaha diagnostic tool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Faul...

Page 411: ... Replace the wire harness Between ECU coupler and Yamaha diagnostic tool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to...

Page 412: ... harness Between ECU coupler and Yamaha diagnostic tool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code nu...

Page 413: ... is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between ECU coupler and Yamaha diagnostic tool coupler yellow blue yellow blue Between Yamaha diagnostic tool coupler and meter assem bly coupler yellow blue yellow blue Connect the Yamaha diagnostic tool and turn the main switch to ON Fault co...

Page 414: ... R W R W R W R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Gy Gy Gy Gy Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L ...

Page 415: ...1 Main switch 3 Ignition fuse 5 Backup fuse 11 Battery 12 Engine ground 13 Main fuse 20 Fuel pump 29 ECU engine control unit 67 Handlebar switch right 70 Engine stop switch A Wire harness B Negative battery sub wire harness ...

Page 416: ... page 8 82 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 77 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 77 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel pump Refer to CHECKING THE FUEL PUMP BODY on page 7 4 Replace the fuel pump a...

Page 417: ...FUEL PUMP SYSTEM 8 72 ...

Page 418: ...ELECTRICAL COMPONENTS 8 73 EAS20089 ELECTRICAL COMPONENTS 2 1 3 4 6 5 8 7 17 18 15 16 14 13 12 11 10 9 20 19 ...

Page 419: ...witch 4 Ignition coil 5 Fuse box 6 Diode 1 7 Starter relay 8 Main fuse 9 Rectifier regulator 10 ECU engine control unit 11 Diode 2 12 Diode 3 13 Diode 4 14 Battery 15 Rear brake light switch 16 O2 sensor 17 Gear position switch 18 Oil pressure switch 19 Radiator fan motor 20 Horn ...

Page 420: ...ELECTRICAL COMPONENTS 8 75 2 3 4 5 12 11 10 9 8 7 1 6 ...

Page 421: ... fan motor relay 3 Fuel pump 4 Fuel injector 5 Throttle body sensor assembly 6 Lean angle sensor 7 Starting circuit cut off relay 8 Turn signal relay 9 Speed sensor 10 Crankshaft position sensor 11 Coolant temperature sensor 12 Air induction system solenoid ...

Page 422: ...MPONENTS 8 77 EAS30549 CHECKING THE SWITCHES L W B R W R B B L W R W R B Br Y Br Y Br R B R L Y R LOCK OFF ON R Br RB R L Y Dg Br W L B B Br Y B Y L Y Ch Br Y L Y Y B Y L B L B Y Ch Dg Br W Br P 1 10 5 2 3 4 9 8 7 6 ...

Page 423: ...RICAL COMPONENTS 8 78 1 Main switch 2 Start switch 3 Engine stop switch 4 Front brake light switch 5 Rear brake light switch 6 Horn switch 7 Turn signal switch 8 Pass switch 9 Dimmer switch 10 Clutch switch ...

Page 424: ...mes The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by There is continuity between red and brown red black red and blue yellow whe...

Page 425: ...lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check Bulb for continuity with the ...

Page 426: ... extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Center cover Passenger seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU engine control unit 1 Turn the main switch to OFF 2 Replace the ECU engine control unit Refer to REMOVING THE ECU engine con trol unit on page 8 81 Refer to INSTALLI...

Page 427: ...of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid batte...

Page 428: ... remove it from the vehicle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger ...

Page 429: ...e charging time suitable for the open circuit voltage f 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 g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant ...

Page 430: ... the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Starting circuit cut off relay 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Recommended lubricant Dielectric grease Pocket tester 908...

Page 431: ...Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery lead L B R Y Y B G Y L 2 1 2 Negative battery lead Result Relay operate OK Relay do not operate Re place Po...

Page 432: ...obe yel low black 3 Negative tester probe sky blue 1 Diode 2 No continuity Positive tester probe red white 4 Negative tester probe blue white 5 No continuity Positive tester probe blue white 5 Negative tester probe red white 4 Diode 3 Continuity Positive tester probe black 6 Negative tester probe blue yellow 7 No continuity Positive tester probe blue yellow 7 Negative tester probe black 6 Diode 4 ...

Page 433: ...gnition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1 k to the ig nition coil as shown c Measure the secondary coil resistance Resistance kΩ Pocket tester 90890 03112 Analog pocke...

Page 434: ... position sensor resistance Out of specification Replace the stator coil assembly Stator coil Crankshaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS30561 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace a Co...

Page 435: ...b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil assembly Stator coil Crankshaft position sensor a Connect the digital circuit tester to the stator coil coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Test harness lean an...

Page 436: ...sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 100 to the fuel sender terminals as shown b Move the fuel sender float to minimum 3 and maximum 4 level position c Measure the fuel sender resistance Charging voltage 14 1 14 9 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Positive battery termina...

Page 437: ...wheel and slowly rotate it e Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS30577 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Me...

Page 438: ...SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester Ω 1 to the air in duction system solenoid terminal as shown c Measure the air induction system solenoid re sistance EAS31088 CHECKING THE GEAR POSITION SWITCH 1 Remove Drive sprocket cover R...

Page 439: ...egative tester probe Switch terminal a 1st position Continuity Positive tester probe white 2 Negative tester probe Switch terminal b 2nd position Continuity Positive tester probe pink 3 Negative tester probe Switch terminal c 3rd position Continuity Positive tester probe yellow white 4 Negative tester probe Switch terminal d 4th position Continuity Positive tester probe white red 5 Negative tester...

Page 440: ...ELECTRICAL COMPONENTS 8 95 ...

Page 441: ...T OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL 9 5 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 6 DIAGNOSTIC CODE ACTU...

Page 442: ...pump Faulty fuel pump Clogged overflow filter Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or...

Page 443: ...ft shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS30605 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn ...

Page 444: ...lty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS30610 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod b...

Page 445: ...ry Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Faulty brake light switch Too many electrical accessories Incorrect connection Faulty tail brake light assembly Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wir...

Page 446: ...ignals are received from the O2 sensor 30 Latch up detected 33 Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 ig nition coil 34 Cylinder 2 ignition coil open or short circuit detected in the primary lead of the cylinder 2 ig nition coil 39 Fuel injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Speed sensor ...

Page 447: ...e air pres sure Set the engine stop switch to and then operate the throttle while pushing the start switch If the dis play value changes the per formance is OK 05 Air temperature Displays the air temperature Compare the actually mea sured air temperature with the meter display value 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displa...

Page 448: ...he detected cylinder numbers When all cylinder numbers are shown the display re peats the same process 11 Data error for ISC idle speed control learning val ues 61 Malfunction history code dis play No history 00 History exists Fault codes 12 70 If more than one code number is detected the display alternates every two seconds to show all the detected code numbers When all code numbers are shown the...

Page 449: ... No Item Actuation Procedure 30 Cylinder 1 ignition coil Actuates cylinder 1 ignition coil five times at one second intervals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the ignition coil is actuated Check that a spark is gener ated five times Connect an ignition check er 31 Cylinder 2 ignition coil Actuates cylinder 2 ignition coil five times at one second inte...

Page 450: ...hat the fuel pump is actuated five times by listen ing for the operating sound 51 Radiator fan motor relay Actuates the radiator fan mo tor relay five times at five second intervals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the relay is actuat ed Check that the radiator fan motor relay is actuated five times by listening for the op erating sound 52 Headlight r...

Page 451: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 10 ...

Page 452: ...r position switch 52 Turn signal relay 53 Handlebar switch left 54 Pass switch 55 Dimmer switch 56 Horn switch 57 Horn 58 Clutch switch 59 Turn signal switch 60 Rear turn signal light left 61 Rear turn signal light right 62 Front turn signal light left 63 Front turn signal light right 64 Headlight right 65 Headlight left 66 Auxiliary light 67 Handlebar switch right 68 Front brake light switch 69 S...

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Page 455: ... R W R B R Y Sb W W R Gy L Y G B B B B B B B B B R R R R B B B B W B B B W W W W Br Br R R R R L L B R P Br R R L Y B R Br R B R L Y R W W W G L Y B L Gy R W W W B R R L W R W R L W R W L Y B B G W R B Y W B B L Br W P W L Y B B L B W B B B L Gy G P B R W Y G B L L L L W Y B L B Y L B L B L B L P B W Y Y W Y B B W Br R P W R W L W Br W B R G B B Y R B G Y O B Gy R Gy G B L B L Y G B L P L R L R G ...

Page 456: ... B B Gy B B B B B B B B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 49 31 31 50 51 52 53 54 55 56 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 75 74 76 77 57 A B B C A A B A C ...

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