Yamaha YZFR1W Service Manual Download Page 160

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REAR BRAKE

4-38

EAS22560

INTRODUCTION

WARNING

EWA14100

Disc brake components rarely require dis-
assembly. Therefore, always follow these
preventive measures:
• Never disassemble brake components

unless absolutely necessary.

• If any connection on the hydraulic brake

system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.

• Never use solvents on internal brake

components.

• Use only clean or new brake fluid for

cleaning brake components.

• Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

• Avoid brake fluid coming into contact

with the eyes as it can cause serious
injury.

• FIRST AID FOR BRAKE FLUID ENTERING

THE EYES:

• Flush with water for 15 minutes and get

immediate medical attention.

EAS22570

CHECKING THE REAR BRAKE DISC

1. Remove:

• Rear wheel

Refer to "REAR WHEEL" on page 4-14.

2. Check:

• Brake disc

Damage/galling

→

Replace.

3. Measure:

• Brake disc deflection

Out of specification

→

Correct the brake

disc deflection or replace the brake disc.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-25.

4. Measure:

• Brake disc thickness

Measure the brake disc thickness at a few
different locations.
Out of specification

→

Replace.

Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-25.

5. Adjust:

• Brake disc deflection

Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-25.

6. Install:

• Rear wheel

Refer to "REAR WHEEL" on page 4-14.

EAS22580

REPLACING THE REAR BRAKE PADS

NOTE:

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove :

• Screw plug “1”
• Brake pad pin “2”
• Brake caliper “3”
• Brake pad spring

2. Remove :

• Brake pads “1”

(along with the brake pad shims “2”)

Brake disc deflection limit

0.15 mm (0.0059 in)

Brake disc thickness limit

4.5 mm (0.18 in)

Rear brake disc bolt

30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®

Summary of Contents for YZFR1W

Page 1: ...2007 MOTORCYCLE SERVICE MANUAL Model YZFR1W 4C8281972000 4C8281972000 ...

Page 2: ...YZFR1W SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition October 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable N...

Page 4: ...age 1 Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruc...

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

Page 6: ... FEATURES 1 2 FI SYSTEM 1 3 IMPORTANT INFORMATION 1 12 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 12 REPLACEMENT PARTS 1 12 GASKETS OIL SEALS AND O RINGS 1 12 LOCK WASHERS PLATES AND COTTER PINS 1 12 BEARINGS AND OIL SEALS 1 13 CIRCLIPS 1 13 CHECKING THE CONNECTIONS 1 14 SPECIAL TOOLS 1 15 ...

Page 7: ...AS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 8: ...becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume accordi...

Page 9: ...position sensor for throttle cable pulley crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant tem perature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection tim ing is determined through the signals from the crankshaft position sensor...

Page 10: ...r easy to use torque even in a high revving engine The YCC I system calculates the value from the engine revolution number and throttle opening rate activates the intake air funnel with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds Aims and advantages of using YCC T system Increase...

Page 11: ...practical use range Intake pipe length switching control using the motor The intake pipe length switching operation in a minute time is now available by means of the motor drive using the electronic control The smooth power characteristic is provided which does not let an operator feel the switching action by the optimization of its switching revolution number and the most suitable application of ...

Page 12: ... CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sens ing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 18 Atmospheric pressure sensor 19 Intake funnel servo mot...

Page 13: ...ral switch 7 Atmospheric pressure sensor 8 Accelerator position two signals 9 Throttle position two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map 18 Idle speed control 19 Calculated throttle valve opening angle 20 Base map 21 Air funnel position Calculation value 22 Inta...

Page 14: ...meter and odometer tripmeter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit CAU...

Page 15: ...play to the stopwatch mode select it by pushing the SELECT button The stopwatch digits will start flashing Release the SELECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stop watch 2 Push the SELECT button to stop the stop watch 3 Push the SELECT button again to reset the stopwatch Split time mea...

Page 16: ...l flash and then the display will indicate a two digit error code NOTE If the display indicates error code 52 this could be caused by transponder interference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobilizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring...

Page 17: ...ght flashes four times per second The indicator light is deactivated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to confirm the selected indicator light activity The control mode changes to the shift timing indicator light activation function ry two seconds To set the shift timing indicator li...

Page 18: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 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 EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 19: ...grease Oil bearings liberally when installing if appropriate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 20: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at ...

Page 21: ...epending on the country When placing an order refer to the list provided below to avoid any mistakes NOTE 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 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 71 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6...

Page 22: ...90890 01423 Damping rod holder YM 01423 4 53 4 54 Oil filter wrench 90890 01426 YU 38411 3 12 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 52 4 57 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 56 4 57 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 23: ...pring compressor 90890 01441 YM 01441 4 52 4 57 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 55 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Compression gauge 90890 03081 Engine compression tester YU 33223 3 10 Tool name Tool No Illustration Reference pages YM A8703 YU 44456 ...

Page 24: ... adapter 22 mm YM 04108 5 23 5 29 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 11 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 11 Universal clutch holder 90890 04086 YM 91042 5 47 5 51 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 25 Tool name Tool No Illustration Reference pages ...

Page 25: ...e installer 4 5 mm YM 04117 5 25 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 25 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 25 Ignition checker 90890 06754 Opama pet 4000 spark checker YU 34487 8 92 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 67 6 11 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 7 Tool name Tool No I...

Page 26: ...8 8 89 8 90 8 91 8 92 8 93 8 94 8 95 8 96 8 97 8 97 8 98 8 99 8 100 Oil pressure adapter H 90890 03139 3 13 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Fuel pressure adapter 90890 03176 YM 03176 7 6 Pressure gauge 90890 03153 YU 03153 3 13 7 6 Camshaft wrench 90890 04143 YM 04143 5 11 5 16 Tool name Tool No Illustration Reference pages ...

Page 27: ...SPECIAL TOOLS 1 21 Ring nut wrench 90890 01507 YM 01507 4 68 4 70 Damper rod holder 22 mm 90890 01365 4 69 4 70 Tool name Tool No Illustration Reference pages ...

Page 28: ...ORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 20 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 39 ...

Page 29: ...ons Overall length 2060 mm 81 1 in Overall width 720 mm 28 3 in Overall height 1110 mm 43 7 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3400 mm 133 9 in Weight With oil and fuel 200 kg 441 lb Maximum load 195 kg 430 lb ...

Page 30: ...ement 3 10 L 3 28 US qt 2 73 Imp qt Oil filter Oil filter type Formed Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 010 0 100 mm 0 0004 0 0039 in Limit 0 18 mm 0 0071 in Outer rotor to oil pump housing clearance 0 090 0 190 mm 0 0035 0 0074 in Limit 0 26 mm 0 0102 in Oil pump housing to inner and outer rotor clearance 0 06 0 13 mm 0 0024 0 0051 in Limit 0 20 mm 0 0079 ...

Page 31: ...n Limit 34 350 mm 1 3524 in Intake B 25 170 25 270 mm 0 9909 0 9949 in Limit 25 070 mm 0 9870 in Exhaust A 33 550 33 650 mm 1 3209 1 3248 in Limit 33 450 mm 1 3169 in Exhaust B 25 192 25 292 mm 0 9918 0 9957 in Limit 25 092 mm 0 9879 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links RH2020 124 Tensioning system Automatic Valve valve seat valve guide Valve clearance col...

Page 32: ...iameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Cylinder head valve s...

Page 33: ...Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 12 mm 0 0047 in Diameter D 76 975 76 990 mm 3 0305 3 0311 in Height H 12 0 mm 0 47 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 17 002 17 013 mm 0 6694 0 6698 in Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Piston ring Top ring Ring type Barrel Dimensions B T 0 9...

Page 34: ...sc 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 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantity 9 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring free length 43 80 mm 1 72 in Spring quantity 6 pcs Transmission Transmiss...

Page 35: ...mperage 6 0 A Output pressure 324 0 kPa 46 1 psi 3 24 kgf cm Fuel injector Model quantity 297500 1110 4 Manufacturer DENSO Throttle body Type quantity 45EIDW 1 Manufacturer MIKUNI ID mark 4C81 00 Throttle valve size 50 Throttle position sensor Resistance 2 0 3 0 kΩ Output voltage at idle 0 63 0 73 V Idling condition Engine idling speed 1150 1250 r min Intake vacuum 22 0 kPa 6 5 inHg 165 mmHg Water...

Page 36: ...IRELLI DIABLO CORSA L Manufacturer model MICHELIN Pilot POWER Wear limit rear 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar Loading condition 90 195 kg 198 430 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar High speed riding Front 25...

Page 37: ...il damper Front fork travel 120 0 mm 4 72 in Fork spring free length 237 5 mm 9 35 in Limit 232 8 mm 9 17 in Collar length 100 0 mm 3 94 in Installed length 223 0 mm 8 78 in Spring rate K1 9 07 N mm 51 79 lb in 0 92 kgf mm Spring stroke K1 0 0 120 0 mm 0 00 4 72 in Inner tube outer diameter 43 0 mm 1 69 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Recommended oil Suspens...

Page 38: ...rt circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GYM Ten hour rate amperage 0 90 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 0 W 4 Auxiliary light 12 V 5 0 W 2 Tail brake light LED Front turn...

Page 39: ...tance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pcs Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω Performance 105 113 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE246BS DENSO Built in self canceling device No Turn signal blinking frequency 75 0 95 0 cycles min Wattage 21 W 2 0 3 4 W Oil level gauge Model manufacturer 5VY SOMIC ISHIKA...

Page 40: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 ...

Page 41: ...bolt water pump side M6 1 10 Nm 1 0 m kg 7 2 ft lb Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kg 11 ft lb Water pump bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover nut M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil cooler bolt M20 1 63 Nm 6 3 m kg 46 ft lb Engine oil drain ...

Page 42: ...ankcase stud bolt M10 10 8 0 Nm 0 8 m kg 5 8 ft lb Crankcase bolt main journal M9 10 See NOTE Crankcase bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M8 1 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M8 5 24 Nm 2 4 m kg 17 ft lb Generator rotor cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover bolt M8 3 22 Nm 2 2 m kg 16 ft lb Drive sprocket ...

Page 43: ...tor cover screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Thermostat assembly stay bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter clutch idler gear bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Clutch boss nut M20 1 115 Nm 11 5 m kg 83 ft lb Use a lock washer Clutch spring bolt M6 6 10 Nm 1 0 m kg 7 2 ft lb Drive sprocket nut M22 1 85 Nm 8 5 m kg 61 ft lb Use a lock washer Bearing plate bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Sh...

Page 44: ...rst tighten the bolts to approximately 20 Nm 2 0 m kg 14 ft lb with a torque wrench follow ing the tightening order 2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm 2 7 m kg 14 ft lb again 3 Retighten the bolts further to reach the specified angle 56 61 Cylinder head tightening sequence Crankcase tightening sequence ...

Page 45: ...Nm 0 5 m kg 3 6 ft lb Under cowling and engine bolt M6 3 5 0 Nm 0 5 m kg 3 6 ft lb Rear view mirror nut M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Front cowling and intake air duct panel screw M5 2 1 3 Nm 0 13 m kg 0 9 ft lb Grip end bolt M6 2 4 0 Nm 0 4 m kg 2 9 ft lb Horn bracket bolt M6 2 11 Nm 1 1 m kg 8 0 ft lb Coolant reservoir bolt M6 2 5 0 Nm 0 5 m kg 3 6 ft lb Left front engine mounting bolt M10 1 45...

Page 46: ...5 1 ft lb Fuel tank bolt rear M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Fuel tank side cover screw M5 2 4 0 Nm 0 4 m kg 2 9 ft lb Rider seat bolt M6 2 7 0 Nm 0 7 m kg 5 1 ft lb Seat lock assembly bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Upper tail cover bolt M5 1 4 0 Nm 0 4 m kg 2 9 ft lb Battery box bolt M6 2 7 0 Nm 0 7 m kg 5 1 ft lb Lean angle sensor bolt M4 2 2 0 Nm 0 2 m kg 1 4 ft lb Footrest bracket bolt M8 ...

Page 47: ... of the axle circumference is positioned on the end face of the fork At this stage it can be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order from the pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening Main frame and rear frame bolt 1 Check the clearance between rear fr...

Page 48: ...r Clutch pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Cylinder head cover mating surface Yamaha bond No 1215 Cylinder head cover semicircular Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Crankcase cover mating surface Yamah...

Page 49: ...g Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting pint and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and spring Shift shaft joint Front wheel oil seal right and left Front axle shaft Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mat...

Page 50: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 52: ...er 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter 6 Main gallery 7 AC magneto drive gear shower 8 Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 AC magneto axle 13 Piston cooler 14 Chain tensioner 15 Intake camshaft 16 Exhaust camshaft ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 A A A A ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Cylinder head 2 Crankshaft ...

Page 63: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 36 1 Water pump 2 Radiator 3 Radiator fan ...

Page 65: ...COOLING SYSTEM DIAGRAMS 2 37 ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 38 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...

Page 67: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING ...

Page 68: ...re to insert the coupler and boot to the stay hole D The speedometer lead should not be strained E To the headlight stay hole F Route by the rear side of the vehicle away from the right auxiliary light lead G Connect after passing over the upper side of the duct H To the turn signal light I Paste the latch of the clamp to be posi tioned toward the rear side of the vehicle J There should be no slac...

Page 69: ...CABLE ROUTING 2 41 ...

Page 70: ...between 0 and 20 mm 0 and 0 79 in from the split of the under bracket G Clamp the leads inside the front fork of the vehicle Point the exit of the horn lead to the left front fork side H Fit in the clamp from the inner side to the outer side of the vehicle so that the return side is positioned upper and the pull side is lower at the upper side of the vehicle above the brake hose I 0 to 30 mm 0 to ...

Page 71: ...CABLE ROUTING 2 43 ...

Page 72: ... drain hose with the radiator bottom end Fasten the clutch cable and coolant reser voir drain hose with a clamp G To the engine H Clamp the coolant reservoir drain hose to the lower side of the vehicle Fasten the clutch cable and coolant reser voir drain hose with a clamp I 80 to 100 mm 3 15 to 3 94 in J Cut the clamp tip leaving 2 to 4 mm 0 08 to 0 16 in K Route the rear brake light switch lead b...

Page 73: ...CABLE ROUTING 2 45 ...

Page 74: ...e lead through the clamp G To the EXUP servo motor H Pass the fuel tank drain hose and fuel tank breather hose through the hole of the cover from the outside of the water pipe after passing the water hose through first Any direction of the hose cut edge can be accepted I 40 to 60mm 1 57 to 2 36 in J Route the sidestand switch lead by the inside of the water hose and water pipe K Route the oil leve...

Page 75: ...CABLE ROUTING 2 47 ...

Page 76: ...aft position sensor lead with a clamp N All hoses and leads should be routed over the vehicle s upper side above the heat protector O To the fuel pump P To the speed sensor Q Clamp the wire harness winding in and insert it to the frame hole R Install the leads so that the engine ground lead is positioned lower and the battery negative lead to be upper Install the protrusion of each lead to be abov...

Page 77: ...CABLE ROUTING 2 49 ...

Page 78: ...icle and clamp at the junction of the wire harness Fasten the battery negative lead wire har ness and starter motor lead with a clamp B Point the tip of the clamp excessive part to the inside of the vehicle Fasten the wire harness with a clamp C Hold down the clamp tips after passing each lead D Insert the leads to the rear frame hole E Insert the clamp from the vehicle front to the rear side and ...

Page 79: ...CABLE ROUTING 2 51 ...

Page 80: ...ntil the click sound is heard and check that the connector does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings F After item E mentioned above is finished check that the clamp is inserted from the down side a b and c sections are per fectly equipped G This part works as a dropout stopper H Fuel p...

Page 81: ...CABLE ROUTING 2 53 ...

Page 82: ... ADJUSTING THE EXUP CABLES 3 17 CHECKING THE EXUP SERVO MOTOR 3 18 CHECKING THE COOLANT LEVEL 3 18 CHECKING THE COOLING SYSTEM 3 19 CHANGING THE COOLANT 3 19 CHASSIS 3 22 ADJUSTING THE FRONT DISC BRAKE 3 22 ADJUSTING THE REAR DISC BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL 3 23 CHECKING THE FRONT BRAKE PADS 3 23 CHECKING THE REAR BRAKE PADS 3 24 CHECKING THE FRONT BRAKE HOSES 3 24 CHECKING THE REAR...

Page 83: ... THE SIDESTAND 3 35 LUBRICATING THE REAR SUSPENSION 3 35 ELECTRICAL SYSTEM 3 36 CHECKING AND CHARGING THE BATTERY 3 36 CHECKING THE FUSES 3 36 REPLACING THE HEADLIGHT BULBS 3 36 ADJUSTING THE HEADLIGHT BEAMS 3 37 ...

Page 84: ...el hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 13000 km 8000 mi or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Every 42000 km 26600 mi 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhaust sy...

Page 85: ...and fasteners Correct if necessary 14 Brake and clutch lever pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Shift pedal rod pivots Apply lithium soap based grease all purpose grease lightly 16 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 17 Sidestand switch Check operation and replace if necessary 18 Front fork Check operati...

Page 86: ...ervoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 EXUP system Check operation cable free play and pulley position Every 19000 km 12000 mi 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or ...

Page 87: ...R INDUCTION SYSTEM on page 7 9 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 9 3 Remove Pickup rotor cover 1 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a ...

Page 88: ...ver the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table Valve clearance measuring sequence Cylinder 1 2 4 3 A Front A Degrees that the crankshaft is turned counterclockwise B Cylinder C...

Page 89: ...t e Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve pad with molybdenum disulfide grease Lubricate the valve lifter with molybdenum disulfide oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake camshafts timing chain and camshaft caps NOTE Refer to CAMSHAFTS on page...

Page 90: ...hose 5 Install Fuel tank Refer to FUEL TANK on page 7 1 6 Start the engine and let it warm up for sev eral minutes 7 Check Engine idling speed 8 Adjust Throttle body synchronization Basic procedure a Start the engine warm it up for several minutes and then let it run at the specified engine idling speed b Turn the bypass air screw 1 with a white paint mark out a little and then turn it in fully c ...

Page 91: ...andard turn out the bypass air screws of the other throttle bod ies to adjust them NOTE Do not turn out the bypass air screw of the throttle body with the lowest vacuum pres sure After each step rev the engine two or three times each time for less than a second and check the synchronization again If an air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throttle body NO...

Page 92: ...ls 4 Remove Spark plugs CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 5 Check Spark plug type Incorrect Change 6 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 7 Clean Spark plugs with...

Page 93: ...sion 6 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compres sion gauge stabilizes WARNING EWA4C81007 To prevent sparking ground all speak plug leads before cranking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm ...

Page 94: ...to enter the crankcase 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled EAS20790 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several minutes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Lower cowlings Refe...

Page 95: ...Check Engine oil drain bolt gasket 8 Install Engine oil drain bolt along with the gasket 9 Fill Crankcase with the specified amount of the recom mended engine oil 10 Install Engine oil filler cap Lower cowlings Refer to GENERAL CHASSIS on page 4 1 11 Start the engine warm it up for several minutes and then turn it off 12 Check Engine for engine oil leaks Oil filter wrench 90890 01426 YU 38411 Oil ...

Page 96: ...lery bolt 1 WARNING EWA12980 The engine muffler and engine oil are extremely hot 4 Install Oil pressure gauge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification Adjust 6 Install Main gallery bolt CAUTION ECA4C81014 Be careful to tighten too much Pressure gauge 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Engine oil pressure 230 kPa 2 3 psi 32 71 k...

Page 97: ...l the specified clutch cable free play is obtained c Tighten the locknuts 1 EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank side covers Fuel tank Refer to FUEL TANK on page 7 1 2 Remove Air filter case cover 1 Refer to GENERAL CHASSIS on page 4 1 3 Check Air filter element 1 Damage Replace NOTE The air filter needs more frequent service ...

Page 98: ...ling the air filter element into the air filter case cover make sure that the sealing surfaces are aligned to prevent any air leaks 6 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Throttl...

Page 99: ...damage Replace Loose connection Connect properly CAUTION ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 CAUTION ECA4C81016 To install the fuel tank check that the breather hose is not folded or pinched by the fuel tank EAS21080 CHECKING THE EXHAUST SYSTEM The...

Page 100: ...y a 5 Adjust EXUP cable free play a Turn the main switch to ON b Check the EXUP pulley position c Projection of the EXUP pulley position is between 1 and 2 d Loosen the both locknuts 3 e Turn the both adjusting nuts 4 in or out f Tighten the both locknuts Exhaust pipe nut 20 Nm 2 0 m kg 14 ft lb Exhaust pipe and exhaust valve pipe bolt 12 Nm 1 2 m kg 8 7 ft lb Exhaust valve pipe and catalist pipe ...

Page 101: ...imes EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove Lower cowlings Right side cowling Refer to GENERAL CHASSIS on page 4 1 3 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant...

Page 102: ...ove Coolant reservoir Coolant reservoir hose 3 Disconnect Coolant reservoir cap 1 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 2 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follo...

Page 103: ...N ECA13480 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different ty...

Page 104: ...p for several minutes and then stop it 17 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 18 NOTE Before checking the coolant level wait a few minutes until the coolant has settled 18 Install Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4 1 ...

Page 105: ...ly an accident Therefore check and if necessary bleed the brake system CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the center of the footrest bracket bolt to the center of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 ...

Page 106: ...luids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake f...

Page 107: ...ck Brake hose Brake fluid leakage Replace the dam aged hose Refer to FRONT BRAKE on page 4 20 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose clamp 2 Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the front brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE o...

Page 108: ...derably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plas...

Page 109: ...EAS21410 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain CAUTION 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 swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface ...

Page 110: ... chain since they may contain sol vents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gen...

Page 111: ... aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 59 6 Measure Steering head tension NOTE Make sure all of the cables and wires are prop erly routed a Point the front wheel straight ahead b Install a plastic locking tie 1 loosely around the end of the handlebar as shown c Hook a ...

Page 112: ... scratches Replace Oil seal 2 Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 50 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13150 Al...

Page 113: ...si tions Minimum 8 Standard 5 Maximum 0 Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound damping adjust posi tions Minimum 26 click s out Standard 10 click s out Maximum 1 click s out With the adjusting screw fully turned in Direction a Compression damping is increased suspension is harder Direction b Compression da...

Page 114: ...he adjusting ring with the stopper 2 Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 1 Standard 5 Maximum 9 Directio...

Page 115: ...ng procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression damping fast com pression damping adjusting positions Minimum 4 turn s out Standard 3 turn s out Maximum 0 turn s out With the adjusting screw fully turned in Dir...

Page 116: ...l the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tire air pressure measured on cold tires Loading condit...

Page 117: ...ARNING EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cabl...

Page 118: ...ND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Molybdenum disulfide grease ...

Page 119: ...ght bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulbs with the headlight bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and ...

Page 120: ...ht beam vertically a Turn the adjusting screw 1 in direction a or b 3 Adjust Headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left headlight Right headlight 4 Install Front cowling inner panels Refer to GENERAL CHASSIS on page 4 1 Direction a Headlight beam is raised Direction b Headlight beam is lowered Direction a Headlight beam moves to the right Direction b Headlight...

Page 121: ...4 26 REMOVING THE FRONT BRAKE CALIPERS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 28 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 29 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 30 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 30 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 31 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 31 REA...

Page 122: ...STEERING HEAD 4 61 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 64 DISPOSING OF A REAR SHOCK ABSORBER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE CONNECTING ARM AND RELAY ARM 4 65 INSTALLING THE RELAY ARM 4 65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 SWINGARM 4 66 REMOVING THE SWINGARM 4 68 CHECKING...

Page 123: ...ob Parts to remove Q ty Remarks 1 Rider seat 2 Passenger seat 1 3 Battery negative lead 1 4 Battery positive lead 1 5 ECU engine control unit 1 6 ECU lead coupler 1 Disconnect 7 ECU cover 1 8 Battery band 1 9 Battery 1 10 Battery seat 1 For installation reverse the removal proce dure ...

Page 124: ... turn signal light lead coupler 2 Disconnect 4 Lower cowling 2 5 Lower cowling front cover 1 6 Intake air duct panel 2 7 Intake air temperature coupler 1 Disconnect 8 Meter assembly coupler 1 Disconnect 9 Front cowling 1 10 Rear intake air duct 2 11 Front intake air duct 2 12 Rear view mirror 2 13 Windshield 1 For installation reverse the removal proce dure ...

Page 125: ...senger seat Refer to GENERAL CHASSIS on page 4 1 Muffler Refer to ENGINE REMOVAL on page 5 1 1 Upper tail cover 1 2 Tail brake light lead coupler 1 Disconnect 3 Turn signal light licence plate light lead coupler 4 Disconnect 4 Mud guard assembly 1 5 Lower tail cover 1 6 Tail brake light 1 For installation reverse the removal proce dure ...

Page 126: ...efer to FUEL TANK on page 7 1 1 Air filter case cover 1 2 Air filter 1 3 Intake funnel servo motor rod assembly 1 4 Intake funnel joint 2 5 Intake funnel 2 6 Intake funnel rod 2 7 Bushing 2 5 8 Air induction system hose 1 9 Crankcase breather hose 1 10 Air filter case 1 11 Intake funnel servo motor 1 For installation reverse the removal proce dure ...

Page 127: ...After assembly make sure that the intake funnel smoothly moves to the contacting surface between upper stopper and lower seating position when it is moved by hand Make sure that the intake funnel smoothly strokes from the upper position to the seating position by its own weight Air filter case Intake funnel joint bolt 1 CAUTION ECA4C81022 Do not remove the bolts from the intake funnel joint Intake...

Page 128: ...gnostic mode and select the diagnostic code number 34 Refer to FUEL INJECTION SYSTEM on page 8 29 b Set the engine stop switch to c Check that the intake funnel operate smoothly strokes from the upper position to the lower seating position ...

Page 129: ...th a screwdriver then pull the fastener out EAS21850 INSTALLING THE COVER 1 Install Rear fender Tail cover NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin is flush with the fastener s head ...

Page 130: ... 3 Left brake hose holder 1 4 Right brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Collar left and right 2 11 Dust cover left and right 2 12 Front wheel 1 13 Front brake disc left and right 2 For installation reverse the removal proce dure ...

Page 131: ...RONT WHEEL 4 9 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 1 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 132: ... FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel turns...

Page 133: ...Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put...

Page 134: ...pplies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips 2 Lift the wheel up between the fork legs 3 Insert the wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Tighten Front wheel axle bolt Front wheel axle pinch bolt CAUTION ECA4C81001 Before tightening the wheel axle push do...

Page 135: ...RONT WHEEL 4 13 WARNING EWA13490 Make sure the brake cable is routed prop erly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers on to the brake discs ...

Page 136: ... 1 Rear brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left adjusting block 1 8 Right adjusting block 1 9 Rear wheel 1 10 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 137: ...ocket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Dust cover 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal proce dure ...

Page 138: ...REAR WHEEL 4 16 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 139: ...ut 2 4 Remove Wheel axle nut 1 Wheel axle Rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear ...

Page 140: ...ng nuts in stages and in a crisscross pattern EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with 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 11 EAS22160 INSTALLING TH...

Page 141: ...ING EWA13500 Make sure the brake hose is routed prop erly Rear wheel axle nut 150 Nm 15 0 m kg 108 ft lb Rear brake caliper bolt front side 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear side 22 Nm 2 2 m kg 16 ft lb ...

Page 142: ...ing the front brake pads Order Job Parts to remove Q ty Remarks 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Brake pad 4 7 Bleed screw 1 For installation reverse the removal proce dure ...

Page 143: ...r cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch lead connector 1 Disconnect 9 Union bolt 1 10 Copper washer 2 11 Brake hose 1 12 Brake master cylinder holder 1 13 Brake master cylinder 1 14 Front brake light switch 1 For installation reverse the removal pr...

Page 144: ...4 22 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 145: ...ke calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 146: ...rake calipers Order Job Parts to remove Q ty Remarks 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Brake pad 4 5 Brake caliper piston 6 6 Brake caliper piston seal 12 7 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 147: ...CS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the ...

Page 148: ...hen replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove Brake hose holder 1 Brake caliper 2 2 Remove Brake pad clips 1 Brake pad pins 2 Brake pad springs 3 3 Remove Brake pads 1 4 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 5 Install Brake pads Brake pad spring Front brake disc bolt 18 Nm 1 8 ...

Page 149: ...liper 7 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 8 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake ca...

Page 150: ...stons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13600 Whenever a brake caliper is disassembled replace the piston seals EAS22410 ASSEMBLI...

Page 151: ... rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could caus...

Page 152: ...es 4 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove Brake master cylinder holder Brake master cylinder EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Bra...

Page 153: ...the lower bolt There should be 2 2 5 mm 0 08 0 10 in of clearance between the right handlebar switch and the brake master cylinder holder 2 Install Copper washers Brake hose Union bolt WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to th...

Page 154: ...eservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION 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 25 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake...

Page 155: ...moving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad 2 6 Bleed screw 1 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 156: ...n page 3 25 1 Footrest plate 1 2 Brake fluid reservoir cap 1 3 Rear brake fluid reservoir diaphragm holder 1 4 Rear brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Hose joint 1 8 Bush 1 9 Union bolt 1 10 Copper washer 2 11 Brake hose 1 12 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 157: ... Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 158: ...e calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 159: ...ipers Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 160: ...CKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification...

Page 161: ...rew d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Brake pad pin Screw plug Brake caliper 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on pa...

Page 162: ...ING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton c Remove the brake caliper piston seals EAS22640 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace ...

Page 163: ...tion Refer to CABLE ROUTING on page 2 39 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Brake caliper 3 Install Brake pad shims Brake pads Brake pad spring Brake pad pin Screw plug Brake caliper 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EW...

Page 164: ...7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Remove Brake master cylinder EAS22720 CHECKING ...

Page 165: ...nsure safe vehicle operation Refer to CABLE ROUTING on page 2 39 CAUTION ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown 2 Fill Brake fluid reservoir to the maximum level mark b WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor b...

Page 166: ...always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 5 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 22 6 Adjust Rear brake light o...

Page 167: ...p 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever holder 1 7 Throttle cable housing 1 8 Throttle cable 2 9 Throttle grip 1 10 Front brake light switch lead connector 2 Disconnect 11 Right handlebar switch 1 12 Clutch cable holder 1 13 Brake fluid reservoir tank 1 14 Brake master cylinder holder 1 15 Brake master cylinder 1 16 Steering damper 1 17 ...

Page 168: ...oosen 19 Upper bracket pinch bolt 2 Loosen 20 Steering stem nut 1 Loosen 21 Upper bracket 1 22 Left handlebar 1 23 Right handlebar 1 For installation reverse the removal proce dure Removing the handlebars Order Job Parts to remove Q ty Remarks ...

Page 169: ...ar as this may dangerously weaken it EAS22900 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 Right handlebar switch 1 NOTE Align the projection a on the right handlebar switch with the hole b on the right handlebar 3 Install Brake master cylinder holder 1 CAUTION ECA14260 Install...

Page 170: ... the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried 8 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 8 EAS4C81004 CHE...

Page 171: ...HANDLEBARS 4 49 ...

Page 172: ...T WHEEL on page 4 8 Front brake caliper Refer to FRONT BRAKE on page 4 20 Side cowling Refer to GENERAL CHASSIS on page 4 1 1 Front fender 1 2 Handlebar pinch bolt 1 Loosen 3 Upper bracket pinch bolt 1 Loosen 4 Cap bolt 1 Loosen 5 Lower bracket pinch bolt 1 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure ...

Page 173: ...g 1 3 Damper adjusting rod 1 4 Damper adjusting rod locknut 1 5 Washer 1 6 Spacer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Inner tube 1 16 Outer tube 1 For assembly reverse the disassembly pro cedure ...

Page 174: ... loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper adjusting rod Spacers 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 NOT...

Page 175: ... inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod assembly 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Damper adjusting rod Bends damage Replace CAUTION ECA14200 The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu...

Page 176: ...e components are clean 1 Install Damper rod assembly 1 Inner tube 2 Damper rod assembly bolt Cooper washer WARNING EWA4C81002 Always use new copper washer CAUTION ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Damper rod assemb...

Page 177: ...over the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Washer Oil seal 1 with the fork seal driver 2 6 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install Dust seal 1 with the fork seal driver 2 8 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 014...

Page 178: ...stroke the damper rod slowly because the fork oil may spurt out 11 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any resid ual air 12 Measure Front fork leg oil level a Out of specification Correct 13 Install Damper adjusting rod locknut 1 Fork spring 2 Spacer 3 Damper adjusting rod 4 Ca...

Page 179: ...t h Install the nut 1 and position it as speci fied b i Set the cap bolt distance c to specifica tion j Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt k Hold the cap bolt and tighten the damper adjusting rod locknut to specification l Remove the rod holder and fork spring compressor Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 Rod pull...

Page 180: ...racket pinch bolts 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Handlebar pinch bolt 3 Upper bracket pinch bolt 4 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 29 Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb Cap bolt 23 Nm 2 3 m kg 17 ft lb Handlebar pinch bolt 17 N...

Page 181: ...nt fork legs Refer to FRONT BRAKE on page 4 20 Handlebar Refer to HANDLEBARS on page 4 45 1 Main switch lead coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar assembly 1 5 Steering stem nut 1 6 Upper bracket 1 7 Front brake hose joint 1 8 Horn lead connector 1 Disconnect 9 Horn 1 10 Horn bracket 1 11 Lower bracket cover 1 12 Lock washer 1 13 Upper ring nut 1...

Page 182: ...ring cover 1 18 Bearing inner race 2 19 Upper bearing 1 20 Lower bearing 1 21 Dust seal 1 22 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 183: ...the bearing races 1 from the steering head pipe 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 races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head i...

Page 184: ... AND ADJUSTING THE STEERING HEAD on page 3 27 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 58 NOTE Temporarily tighten the upper and lower bracket pinch bolts Recommended lubricant Lithium soap based grease ...

Page 185: ...GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 1 4 Self locking nut 1 5 Rear shock absorber assembly 1 6 Oil seal bearing collar 4 3 4 7 Collar self locking nut bolt 1 1 1 8 Connecting arm 1 9 Oil seal bearing collar 2 1 1 10 Catalytic converter pipe stay 1 11 Relay arm 1 For installation reve...

Page 186: ...e through the rear shock absorber at a point 15 20 mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that...

Page 187: ...0 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Collars Bearings 2 Install Rear shock absorber assembly NOTE Install the connecting arm front bolt from the left 3 Tighten Rear shock absorber upper bracket nut Rear shock absorber assembly lower nut Relay arm to swingarm nut Recommended lubricant Lithium soap base grease Installed depth a 1 0 mm 0 04 in Installed depth b 4 0 mm 0 16 in A L...

Page 188: ...ORBER ASSEMBLY on page 4 63 Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Right footrest bracket 1 2 Drive chain adjusting bolt locknut 2 2 3 Drive chain guard 1 4 Rear fender 1 5 Brake hose holder 1 6 Pivot shaft nut washer 1 1 7 Pivot shaft ring nut washer 1 1 8 Pivot shaft 1 9 Swingarm 1 10 Drive chain 1 11 Dust cover 2 12 Washer 1 13 Drive chain guide 1 14 Spacer 1 15 Bearing 2 ...

Page 189: ...SWINGARM 4 67 For installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks ...

Page 190: ...asure the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust cov ers 4 Remove Drive chain Refer to...

Page 191: ...en a bent pivot shaft 3 Wash Pivot shaft Dust covers Spacer Washers Bearings 4 Check Dust covers 1 Spacer 2 Washer 3 Damage wear Replace Bearings 4 Damage pitting Replace EAS23380 INSTALLING THE SWINGARM 1 Lubricate Bearings Spacers Dust covers Pivot shaft 2 Install Bearing 1 Bearing 2 Washer 3 Damper rod holder 22 mm 90890 01365 Recommended cleaning solvent Kerosene Recommended lubricant Molybden...

Page 192: ... Install Pivot shaft nut 1 NOTE Lubricant the pivot shaft nut threads and mat ing surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 5 Swingarm 6 Pivot shaft A Left side B Right side Pivot shaft 7 Nm 0 7 m kg 5 1 ft lb Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut 65 Nm 6 5 m kg 47 ft lb Ring nut wrench 90890 01507 YM...

Page 193: ... 71 EAS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Swingarm Refer to SWINGARM on page 4 66 1 Drive chain guard 1 2 Drive chain 1 For installation reverse the removal proce dure ...

Page 194: ... the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 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 it CAUTION ECA4C81003 This vehicle has a drive cha...

Page 195: ...CKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 18 EAS23490 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive chain 1 Drive sprocket 2 Washer Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Recommended lubricant Engine oil...

Page 196: ...st Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 CAUTION 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 swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits Drive chain slack 30 0 40 0 mm 1 18 1 57 in ...

Page 197: ...CHAIN DRIVE 4 75 ...

Page 198: ...AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 GENERATOR 5 30 REMOVING THE GENERATOR 5 32 INSTALLING THE GENERATOR 5 32 STARTER CLUTCH 5 34 REMOVING THE STARTER CLUTCH 5 35 CHECKING THE DAMPER 5 35 CHECKING THE STARTER CLUTCH 5 35 INSTALLING THE STARTER CLUTCH 5 36 CRANKSHAFT POSITION SENSOR 5 37 REMOVI...

Page 199: ...ECKING THE OIL NOZZLES 5 61 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL WATER PUMP ASSEMBLY 5 62 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 67 CHECKING THE CRANKCASE 5 67 CHECKING THE BEARING AND OIL SEALS 5 67 ASSEMBLING THE CRANKCASE 5 67 CRANKSHAFT 5 69 REMOVING THE CONNECTING RODS AND PISTONS 5 71 REMOVING THE CRANKSHAFT ASSEMBLY 5 71 CHECKING THE CYLINDER AND...

Page 200: ...CHECKING THE TRANSMISSION 5 90 INSTALLING THE TRANSMISSION 5 91 ...

Page 201: ...rks Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 1 Locknut 2 2 Shift rod 1 3 Sift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 8 Plate 1 For installation reverse the removal proce dure ...

Page 202: ...page 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 1 Right footrest bracket 1 2 Protector cover 1 3 Protector 1 4 EXUP valve pulley cover 1 5 EXUP cable 2 6 EXUP servo motor bracket 1 7 EXUP servo motor 1 8 O2 sensor 1 9 Muffler cover 2 10 Muffler 2 11 Gasket 2 12 Catalyst pipe assembly 1 13 Gasket 1 14 Exhaust valve pipe assembly 1 15 Exhaust valve pipe gasket 1 16 Exhaust pipe assembly...

Page 203: ...ENGINE REMOVAL 5 3 For installation reverse the removal proce dure Removing the exhaust pipe Order Job Parts to remove Q ty Remarks ...

Page 204: ...alve pipe Order Job Parts to remove Q ty Remarks 1 Washer 1 2 Pulley 1 3 Collar 1 4 Plate 1 5 Spring 1 6 EXUP pulley bracket 1 7 Housing 1 8 Gasket 1 9 Collar 1 10 Shaft arm 1 11 Exhaust valve pipe 1 For assembly reverse the disassembly pro cedure ...

Page 205: ... on page 6 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Battery negative lead 1 2 Battery positive lead 1 3 Clutch cable 1 4 Engine ground lead 2 5 Stator coil assembly coupler 1 Disconnect 6 Crankshaft position sensor coupler 1 Disconnect 7 Oil level switch connector 1 Disconnect 8 Neutral switch connector 1 Disconnect 9 Spee...

Page 206: ...gine mount collar outer 1 3 Engine mount collar center 1 4 Engine mount collar inner 1 5 Engine mounting bolt front left side 1 6 Locknut 1 7 Engine mounting bolt rear lower side 1 8 Locknut 1 9 Engine mounting bolt rear upper side 1 10 Engine mounting adjust bolt 2 11 Engine 1 For installation reverse the removal proce dure ...

Page 207: ... mount bolt front left side 1 temporary tighten 5 Install Engine mount collar inner 1 Engine mount collar center 2 Engine mount collar outer 3 Right front engine mount bolt 4 temporary tighten 6 Tighten Engine mounting adjust bolts NOTE Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mounting adjust bolts 7 Tighten Upper locknut 1 Lower locknut 2 Engine mounting...

Page 208: ...ut 8 Tighten Left front engine mounting bolt 1 9 Tighten Right front engine mounting bolt 1 Upper locknut 51 Nm 5 1 m kg 37 ft lb Lower locknut 51 Nm 5 1 m kg 37 ft lb Engine mounting bolt front left side 45 Nm 4 5 m kg 33 ft lb Engine mounting bolt front right side 45 Nm 4 5 m kg 33 ft lb ...

Page 209: ...s Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 Radiator assembly Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 1 Ignition coil 4 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide top side 1 6 Cylinder identification sensor 1 7 O ring 1 For installation reverse the removal...

Page 210: ...T POSITION SEN SOR on page 5 37 1 Camshaft sprocket bolt 4 Loosen 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 6 Exhaust camshaft cap 3 7 Dowel pin 6 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For installation reverse the removal proce dure ...

Page 211: ...NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket 5 Remove Camshaft caps 1 Dowel pins CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Re...

Page 212: ...camshaft caps NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 Camshaft lobe dimension limit Intake A 34 450 34 550 mm 1 3563 1 3602 in Limit 34 350 mm 1 3524...

Page 213: ... the camshaft sprocket and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TEN SIONER 1 Remove Timing chain te...

Page 214: ...pring and timing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and push the timing chain tensioner rod 3 NOTE When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2 make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2 Otherwise the timing chain tensioner rod 3 may run of...

Page 215: ... sure the punch mark a on each cam shaft faces up 4 Install Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows I Intake side camshaft cap mark E Exhaust side camshaft cap mark IL Intake left side camshaft cap mark IR Intake right side camshaft cap mark EL Exhaust left side camshaft c...

Page 216: ...haft punch mark a and the camshaft cap arrow mark b 8 Install Gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 CAUTION ECA4C81006 The arrow mark a on the timing chain ten sioner should face up WARNING EWA4C81004 Always use a new gasket 9 Turn Crankshaft several turns clockwise 10 Check T mark a Make sure the T mark on the pickup rotor is aligned with the crankcase mating sur face b C...

Page 217: ...CAMSHAFTS 5 17 11 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 12 Install Pickup coil rotor cover CRANKSHAFT POSITION SENSOR on page 5 37 ...

Page 218: ...arks Engine Refer to ENGINE REMOVAL on page 5 1 Intake camshaft Refer to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4 Coolant pipe 1 5 O ring 1 6 Water pump breather hose 1 For installation reverse the removal proce dure ...

Page 219: ...ium valves with the cylinder head Refer to CHECKING THE VALVE SEATS on page 5 25 Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 6...

Page 220: ...4 0 m kg 29 ft lb with a torque wrench Final tighten the nuts 7 10 to 55 Nm 5 5 m kg 40 ft lb with a torque wrench Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in four stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 15 Cylinder head nut 1st 10 Nm 1 0 m kg 7 2 ...

Page 221: ... 8 3 Intake valve cotter 16 4 Intake valve upper spring seat 8 5 Intake valve spring 8 6 Intake valve oil seal 8 7 Intake valve lower spring seat 8 8 Intake valve 8 9 Intake valve guide 8 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhau...

Page 222: ...VALVES AND VALVE SPRINGS 5 22 For installation reverse the removal proce dure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks ...

Page 223: ...a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach ment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve stem seal 3 Lower spring seat 4 V...

Page 224: ...de installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After 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 Valve stem to valve guide clear ...

Page 225: ... 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide install...

Page 226: ...lves with new valves NOTE When replacing the cylinder head replace the valves without lapping the valve seats and valve faces When replacing the valves or valves guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve g...

Page 227: ...alve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring free length Free length intake 39 ...

Page 228: ...3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Refer to the following embossed marks Intake valve Pink paint mark Exhaust valve 4C8 Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the val...

Page 229: ...te Valve pad 1 Valve lifter 2 with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Recommended lubricant...

Page 230: ...age 4 1 Side cowlings Refer to GENERAL CHASSIS on page 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Stator coil assembly coupler 1 Disconnect 2 Plug 1 3 Generator rotor cover 1 4 Gasket 1 5 Dowel pin 2 6 Generator rotor assembly 1 7 Stator coil assembly 1 8 Dowel pin 2 9 Bearing housing 1 10 Collar 1 11 Bearing 1 ...

Page 231: ...31 12 Stator coil assembly lead holder 1 13 Idler gear 1 14 Idler gear shaft 1 15 Washer 1 16 Bearing 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks ...

Page 232: ...e Generator rotor and starter clutch assem bly 1 3 Remove Idle gear shaft bolt 1 Idle shaft Idle gear 2 EAS24500 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bolt 2 2 Install Generator rotor and starter clutch assem bly 1 3 Install Generator rotor cover gasket Generator rotor cover 1 Idle gear shaft bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Generator rotor cove...

Page 233: ...GENERATOR 5 33 NOTE First tighten the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern ...

Page 234: ...H Removing the starter clutch Order Job Parts to remove Q ty Remarks 1 Generator rotor 1 2 Damper 3 3 Driven gear 1 4 Washer 1 5 Starter clutch drive gear 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 O ring 1 For assembly reverse the removal proce dure ...

Page 235: ...e wear Replace EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch drive gear 1...

Page 236: ...kwise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Generator rotor 1 Damper 2 Driven gear 3 NOTE The hole side of the damper is installed to the generator side Lubricate the engine oil 4 2 Install Starter clutch drive gear 1 Collar 2 Washer 3 Refer to CHECKING THE STARTER CLUTCH on page 5 35 3 Install Washer 1 ...

Page 237: ...e 4 1 Side cowlings Refer to GENERAL CHASSIS on page 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Crankshaft position sensor lead coupler 1 2 Crankshaft position sensor 1 3 O ring 1 4 Pickup rotor cover 1 5 Gasket 1 6 Cover 1 For installation reverse the removal proce dure ...

Page 238: ... each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup rotor cover 1 O ring Crankshaft position sensor 2 Connect Crankshaft position sensor lead coupler Pickup rotor cover 12 Nm 1 2 m kg 8 7 ft lb Crankshaft position sensor bolt 10 Nm 1 0 m kg 7 2 ft lb...

Page 239: ... ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 240: ...e starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 Gasket 2 8 Brush holder 1 9 Rear cover 1 For assembly reverse the removal proce dure ...

Page 241: ...s commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 23 5 mm 0 93 in Mica...

Page 242: ... holder and push the brush inside until it touches the armature 2 Install O rings Rear cover 1 NOTE Align the tab a on the brush holder 2 with the tab b in the starter motor rear cover 3 Install Nut 1 4 Install Starter motor yoke 1 Gasket 2 Starter motor rear cover 3 Starter motor assembling bolts 4 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and star...

Page 243: ...ER 5 43 EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor bolt 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead bolt 7 Nm 0 7 m kg 5 1 ft lb ...

Page 244: ... Refer to GENERAL CHASSIS on page 4 1 Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 245: ... Removing the push lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal proce dure ...

Page 246: ...te 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Muffler 1 14 Spring 3 15 Clutch boss 1 16 Pressure plate 2 1 17 Conical spring washer 1 18 Thrust plate 2 1 19 Clutch housing 1 20 Bearing 1 For installation reverse the removal proce dure ...

Page 247: ...Compression springs Pressure plate 2 Push rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3 Clutch damper spring Clutch damper spring seat 5 Straighten the clutch boss nut rib 1 6 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 7 Remove Clutch boss ...

Page 248: ...age Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure assembly width a of the friction plates and clutch plates Out of specification Adjust NOTE Perform the thickness measurement without applying the oil a Assembly width adjusted by clutch plate 1 and 2 b Select the clutch p...

Page 249: ...utch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replac...

Page 250: ...er shaft pinion gear teeth 1 Push rod teeth 2 Damage wear Replace the push rod and push lever shaft pinion gear as a set 2 Check Push rod bearing Damage wear Replace EAS25240 INSTALLING THE CLUTCH 1 Install Clutch housing 1 Conical spring washer Thrust plate 2 NOTE Align the projection of clutch housing a and hollow of the oil pump drive gear b 2 Install Pressure plate 2 1 Clutch boss 2 NOTE Fit t...

Page 251: ...tch boss nut by staking them with a drift punch at the point aligned with the groove in the axle 4 Install Clutch damper spring seat 1 Clutch damper spring 2 NOTE Install the clutch damper spring as shown in the illustration 5 Lubricate Friction plates Clutch plates with the recommended lubricant 6 Install Friction plate 3 Friction plate 2 Clutch plate 3 Clutch plate 2 Clutch plate 1 1 Clutch boss...

Page 252: ...all Push lever NOTE Install the push lever with the h mark facing toward upper side 11 Install Clutch cover Clutch cover gasket NOTE Install the push rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply oil onto the bearing Apply molybdenum disulfide grease onto the push rod When installing the clutch cover push the push lever and check that the punch ma...

Page 253: ...2 NOTE Tighten the clutch cover bolts in a stages and in a crisscross pattern 13 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE ...

Page 254: ...rm Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer to CLUTCH on page 5 44 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper lever 1 9 Washer 1 10 Oil seal 1 11 Bearing 1 12 Bearing 1 13 Stopper lever spring 1 For installation reverse the removal proce dure ...

Page 255: ...lar Washer 5 Remove Stopper lever spring 1 Stopper screw 2 Stopper lever 3 Washer EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift lever spring 2 Collar 3 Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Washer Stopp...

Page 256: ... with the shift drum segment assembly Lubricate the oil seal lips with lithium soap base grease Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install Washer 1 Circlip 2 4 Install Shift rod Shift arm Refer to ENGINE REMOVAL on page 5 1 5 Install Clutch assembly Refer to CLUTCH on page 5 44 New ...

Page 257: ...to ENGINE REMOVAL on page 5 1 O2 sensor Refer to ENGINE REMOVAL on page 5 1 Muffler Refer to ENGINE REMOVAL on page 5 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer to CLUTCH on page 5 44 Water pump inlet pipe Refer to OIL COOLER on page 6 4 Water pump outlet pipe Refer to OIL COOLER on page 6 4 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch 1 3 ...

Page 258: ... pump assembly drive chain guide 1 13 Collar 1 14 Oil water pump assembly drive sprocket 1 15 Washer 1 16 Oil water pump assembly drive chain 1 17 Dowel pin 1 18 Oil water pump assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 259: ... pump Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Collar 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For assembly reverse the disassembly pro cedure ...

Page 260: ...in and oil water pump assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump Inner rotor to ou...

Page 261: ...RY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS4C81013 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle 1 Da...

Page 262: ...ater pump driven sprocket 1 NOTE 5VY mark of the oil water pump driven gear is installed at oil pump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 60 EAS25030 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install Oil ring Oil water pump assembly 1 Dowel pin Bolts 2 2 Install Washer Oil water pump assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar Recommend...

Page 263: ...pump assembly drive chain guide is upward 4 Install Oil delivery pipe 1 5 Install Relief valve 1 O ring Oil strainer 2 O ring Oil pipe 3 O ring Drain pipe 4 O ring EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Gasket Oil pan 1 Oil level switch 2 Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil delivery pipe bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil straine...

Page 264: ...drain bolt WARNING EWA12820 Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil Engine oil drain bolt 43 Nm 4 3 m kg 31 ft lb ...

Page 265: ...EAD on page 5 18 Generator Refer to GENERATOR on page 5 30 Starter clutch Refer to STARTER CLUTCH on page 5 34 Shift shaft Refer to SHIFT SHAFT on page 5 54 Crankshaft position sensor Refer to CRANKSHAFT POSITION SEN SOR on page 5 37 Clutch Refer to CLUTCH on page 5 44 Oil pump Refer to OIL PUMP on page 5 57 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Timing chain 1 2 Timing chain guide...

Page 266: ...CRANKCASE 5 66 7 Lower crankcase 1 8 Dowel pin 3 9 Damper 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 267: ... crankcase halves separate evenly 4 Remove Dowel pins 5 Remove Crankshaft journal lower bearing from the lower crankcase NOTE Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfac...

Page 268: ... 1 10 and 22 Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase M9 105 mm 4 1 in bolts 1 10 M8 60 mm 2 4 in bolt 11 LOCTITE M8 60 mm 2 4 in bolts 12 16 M8 50 mm 2 0 in bolts 13 15 M6 65 mm 2 5 in bolts 17 18 M6 70 mm 2 8 in bolts 19 21 23 M6 50 mm 2 0 in bolts 20 26 M6 60 mm 2 4 in bolt and washer 22 M6 60 mm 2 4 in bolts 24 25 Following the tightening order loosen the...

Page 269: ...rks Lower crankcase Refer to CRANKCASE on page 5 65 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 For installation reverse the removal proce dure ...

Page 270: ... on page 5 65 Connecting rod and connecting rod caps Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Washer 1 5 Crankshaft drive gear 1 6 Pin 1 7 Pickup rotor 1 For installation reverse the removal proce dure ...

Page 271: ... 3 CAUTION ECA4C81008 Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are debarred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 4 Remove Top ring 2nd ring Oil r...

Page 272: ... as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon...

Page 273: ...ston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in a 5 mm 0 20 in Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 01...

Page 274: ...ing rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolt thre...

Page 275: ...achined face a Thrusting faces 4 places at front and rear b NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment j Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi tion k Tighten the connecting...

Page 276: ...olt until it is at the specified angles q Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 r Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 NOTE The numbers A stamped into the cran...

Page 277: ...re that the Y mark a on the con necting rod faces left when the arrow mark b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Lubricate Crankshaft pins Big end bearings Connecting rod big end inner surface with t...

Page 278: ... connecting rod bolts c After installing the big end bearing assem ble the connecting rod and connecting rod cap once using a single unit of the connect ing rod d Tighten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion sho...

Page 279: ...ning angle method a Clean the connecting rod bolts b Tighten the connecting rod bolts c Put a mark 1 on the connecting rod bolt 2 and the connecting rod cap 3 d Tighten the bolt further to reach the speci fied angle 150 e After the installation check that the section shown a is flush with each other by touch ing the surface WARNING EWA13990 When the bolt is tightened more than the specified angle ...

Page 280: ...JOURNAL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA4C81011 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positi...

Page 281: ...ts 12 16 M8 50 mm 2 0 in bolts 13 15 M6 65 mm 2 5 in bolts 17 18 M6 70 mm 2 8 in bolts 19 21 23 M6 50 mm 2 0 in bolts 20 26 M6 60 mm 2 4 in bolt and washer 22 M6 60 mm 2 4 in bolts 24 25 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque NOTE Lubricate the crankcase bolt threads with engine oil Refer to CRANKCASE on page 5 65 g Remove the lower c...

Page 282: ...ngs If the size is the same for all J1 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively then the bearing size for J1 is EAS26200 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings 1 into the upper crankcase 2 Lubricate Crankshaft journal upper bearings with the recommended lubric...

Page 283: ...ith the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 3 Install Crankshaft 4 Install Crankcase lower Refer to CRANKCASE on page 5 65 5 Install Pin Pickup rotor 1 Drive sprocket 2 Drive sprocket bolt 60 Nm 6 0 m kg 43 ft lb ...

Page 284: ... Separate Refer to CRANKCASE on page 5 65 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Washer 1 6 Shift fork guide bar retainer 2 7 Spring 2 8 Shift fork guide bar 2 9 Shift fork L 1 10 Shift fork R 1 11 Shift drum assembly 1 12 Shift fork C 1 13 Main axle retainer 1 14 Main axle assembly 1 15 Oil pipe 1 16 O ring 2 17 Oil baffle plate 1 ...

Page 285: ...TRANSMISSION 5 85 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 286: ...d pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 287: ... Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 18 Collar 1 19 2nd wheel gear 1 20 Collar 1 21 Oil seal 1 22 Bearing 1 23 Drive axle 1 ...

Page 288: ...TRANSMISSION 5 88 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks ...

Page 289: ... Tighten the bolts until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil pipe 1 Bearing 2 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork g...

Page 290: ...2 Damage pitting Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Tran...

Page 291: ...ft forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle 3 Install Shift fork L 1 and R 2 Drive axle assembly 3 Shift fork guide bar Shift fork guide bar retainer 4 NOTE Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive a...

Page 292: ...TRANSMISSION 5 92 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly ...

Page 293: ...TRANSMISSION 5 93 ...

Page 294: ...R 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 295: ...1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Radiator fan coupler 2 Disconnect 2 Fuse holder stay 1 3 Coolant reservoir tank 1 4 Coolant reservoir hose 1 5 Radiator inlet hose 1 6 Oil cooler outlet hose 1 7 Radiator outlet hose 1 8 Water pump inlet pipe 1 9 O ring 1 10 Radiator 1 ...

Page 296: ...RADIATOR 6 2 11 Radiator fan motor 2 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks ...

Page 297: ...ap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to RADIATOR on page 6 1 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling syst...

Page 298: ...age 3 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 Loosen 3 Washer 1 Disconnect 4 Oil cooler 1 Disconnect 5 O ring 1 6 Water pump outlet pipe 1 7 O ring 1 8 Water jacket joint inlet hose 1 9 O ring 1 10 Water jacket joint 1 11 Stay 1 12 O ring 1 For installation reverse the removal proce dure ...

Page 299: ... NOTE Before installing the oil cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount of the recom men...

Page 300: ...n page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Refer to CHANGING THE COOLANT on page 3 19 1 Thermostat assembly outlet hose 1 2 Thermostat assembly breather hose 1 3 Thermostat assembly 1 4 Thermostat assembly inlet hose 1 5 Band 1 For installation reverse the removal proce dure ...

Page 301: ...h water b Slowly heat the water 3 c Place a thermometer 4 in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature Disassembling the thermostat assembly Order Job Parts to remove Q ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4 O ring 1 For assembly reverse the disassembly pro cedure ...

Page 302: ...SEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 NOTE Install the thermostat with its breather hole a facing up EAS26480 INSTALLING THE THERMOSTAT ASSEM BLY 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part A Fully closed B Fully...

Page 303: ... Remarks Oil water pump assembly Refer to OIL PUMP on page 5 57 Oil pump rotor Refer to OIL PUMP on page 5 57 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 O ring 1 For installation reverse the removal proce dure ...

Page 304: ...crewdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Rubber damper 4 Rubber damper holder 5 Water pump seals Oil seal Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Radiator outlet hose Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP...

Page 305: ...tap water or coolant onto its outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller a 17 2 mm 0 68 in Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1...

Page 306: ...ING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 6 CHECKING THE THROTTLE BODIES 7 6 CHECKING THE FUEL PRESSURE 7 6 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 7 6 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 10 ...

Page 307: ...IS on page 4 1 Passenger seat Refer to GENERAL CHASSIS on page 4 1 1 Fuel tank side cover 2 2 Fuel sender coupler 1 3 Fuel pump coupler 1 4 Fuel tank drain hose 1 5 Fuel tank breather hose 1 6 Fuel hose connector 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel tank top cover 1 10 Fuel pump 1 For installation reverse the removal proce dure ...

Page 308: ...ion surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace the fuel pump assembly...

Page 309: ...nstalled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection hose slide the cover a on the end of the hose in the direction of arrow shown 2 Install Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose Fuel tank side cover NOTE T...

Page 310: ...s coupler 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Throttle servo motor coupler 1 Disconnect 4 Throttle position sensor for throttle valves cou pler 1 Disconnect 5 Throttle position sensor for throttle cable pulley coupler 1 Disconnect 6 Throttle body joint clamp 4 Loosen 7 Throttle cables 2 Disconnect 8 Throttle bodies 1 9 Throttle body joint 3 10 Engine ground 2 11 Heat p...

Page 311: ... 1 Disconnect 4 Cylinder 3 injector coupler 1 Disconnect 5 Cylinder 4 injector coupler 1 Disconnect 6 Sub wire harness 1 7 Negative pressure hose 1 Disconnect 8 Intake air pressure sensor 1 9 Fuel distributor 1 10 Injector 4 11 Throttle position sensor for throttle valves 1 12 Throttle position sensor for throttle cable pulley 1 13 Throttle body assembly 1 For installation reverse the removal proc...

Page 312: ...ri mary injector fuel rail 1 from the primary injector fuel rail WARNING EWA4C81001 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses c Connect the pressure gauge 2 and adapter 3 to the fuel hose fuel tank to pri mary injector fuel rail d Start the engine e Measure the fuel pressure Faulty Rep...

Page 313: ...nsor for throttle cable pulley Refer to ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY on page 7 7 2 Adjust Throttle position sensor for throttle cable pulley angle a Temporary tighten the throttle position sen sor for throttle cable pulley b Check that the throttle valves are fully closed c Connect the throttle position sensor for throttle valves throttle position sensor for thr...

Page 314: ...THROTTLE BODIES 7 8 ...

Page 315: ...b Parts to remove Q ty Remarks 1 Air cut off valve coupler 1 Disconnect 2 Air cut off valve hose 1 1 Disconnect 3 Air cut off valve hose 2 1 Disconnect 4 Air cut off valve hose 3 1 Disconnect 5 Air cut off valve 1 6 Reed valve cap 2 7 Reed valve assembly 2 8 Plate 4 For installation reverse the removal proce dure ...

Page 316: ... to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture 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 Pipes Cracks dam...

Page 317: ...AIR INDUCTION SYSTEM 7 11 ...

Page 318: ...OUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 26 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 32 TROUBLESHOOTING METHOD 8 35 DIAGNOSTIC MODE 8 36 TROUBLESHOOTING DETAILS 8 44 FUEL PUMP SYSTEM 8 65 CIRCUIT DIAGRAM 8 65 TROUBLESHOOTING 8 67 IMMOBILIZER SYSTEM 8 69 CIR...

Page 319: ...STATOR COIL 8 93 CHECKING THE RECTIFIER REGULATOR 8 93 CHECKING THE HORN 8 94 CHECKING THE OIL LEVEL SWITCH 8 94 CHECKING THE FUEL SENDER 8 95 CHECKING THE SPEED SENSOR 8 95 CHECKING THE RADIATOR FAN MOTORS 8 96 CHECKING THE COOLANT TEMPERATURE SENSOR 8 96 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 8 97 CHECKING TH...

Page 320: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 321: ... Neutral switch 14 Sidestand switch 19 ECU engine control unit 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 35 Crankshaft position sensor 40 Lean angle sensor 58 Engine stop switch 64 Clutch switch 79 Ignition fuse 88 Ground 89 Battery negative lead ...

Page 322: ...8 85 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 91 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 91 Replace the ignition coils 6 Check the crankshaft...

Page 323: ...n page 8 81 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 88 Replace the starting circuit cut off relay 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 92 Replace the lean angle sensor 14 Check the entire...

Page 324: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 325: ...itch 4 Main fuse 8 Battery 10 Starter relay 11 Starter motor 12 Starting circuit cut off relay 13 Neutral switch 14 Sidestand switch 58 Engine stop switch 59 Start switch 64 Clutch switch 79 Ignition fuse 88 Ground 89 Battery negative lead ...

Page 326: ...sed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions 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 h...

Page 327: ...ND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 Battery negative lead 15 Ground ...

Page 328: ...ttery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 93 Repair or replace the starter motor 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 41 Repair or replace the starter motor 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 88 Replace the starting circ...

Page 329: ...eck the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 13 Check the entire starting system s wiring Refer to ELECTRIC STARTING SYSTEM on page 8 5 Properly ...

Page 330: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 331: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 4 Main fuse 8 Battery 88 Ground 89 Battery negative lead ...

Page 332: ...ttery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 93 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 93 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to C...

Page 333: ...CHARGING SYSTEM 8 14 ...

Page 334: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 335: ...CU engine control unit 51 High beam indicator light 54 Meter light 62 Dimmer switch 71 Headlight 72 Auxiliary light 74 License plate light 76 Tail brake light 77 Headlight relay on off 78 Headlight relay dimmer 81 Headlight fuse 88 Ground 89 Battery negative lead ...

Page 336: ...headlight and park Refer to CHECKING THE FUSES on page 8 85 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 81 The dimmer switch ...

Page 337: ...eadlight relay dimmer Refer to CHECKING THE RELAYS on page 8 88 Replace the headlight relay 9 Check the entire lighting system s wiring Refer to LIGHTING SYSTEM on page 8 15 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 338: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 339: ...ift timing indicator light 48 Multi function meter 50 Coolant temperature indicator light 52 Left turn signal indicator light 53 Right turn signal indicator light 57 Front brake light switch 60 Turn signal relay 63 Horn switch 65 Turn signal switch 66 Horn 67 Front left turn signal light 68 Front right turn signal light 69 Rear left turn signal light 70 Rear right turn signal light 75 Rear brake l...

Page 340: ... to CHECKING THE FUSES on page 8 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch immobilizer unit assembly 4 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properl...

Page 341: ...et or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the rear brake light switch 4 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit ...

Page 342: ...tem s wiring This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the neutral switch 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the oil level switch 2 Check...

Page 343: ...ge 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 95 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring Replace the meter assembly ...

Page 344: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 345: ...nition and radiator fan motor Refer to CHECKING THE FUSES on page 8 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on ...

Page 346: ...COOLING SYSTEM 8 27 NG OK 7 Check the entire cooling system s wiring Refer to COOLING SYSTEM on page 8 25 Properly connect or repair the cooling system s wiring This circuit is OK ...

Page 347: ...COOLING SYSTEM 8 28 ...

Page 348: ...FUEL INJECTION SYSTEM 8 29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 349: ...CU engine control unit 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 25 Injector 1 26 Injector 2 27 Injector 3 28 Injector 4 32 EXUP servo motor 33 Speed sensor 34 Intake air temperature sensor 35 Crankshaft position sensor 36 Coolant temperature sensor 37 Intake air pressure sensor 38 Atmospheric pressure sensor 39 Cylinder identification sensor 40 Lean...

Page 350: ...r fuel reservoir trip meter stop watch LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking engine trouble warning light The engine trouble warning light comes on f...

Page 351: ...tion sensor No normal signals are received from the cylinder identification sensor Malfunction of electric starting system Unable Able 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit detected Able Able 14 Intake air pressure sensor pip...

Page 352: ...epending on the num ber of faulty cylinders 34 Ignition coil 2 faulty ignition Malfunction detected in the pri mary wire of the ignition coil 2 Able depending on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 35 Ignition coil 3 faulty ignition Malfunction detected in the pri mary wire of the ignition coil 3 Able depending on the num ber of faulty cylinders Able d...

Page 353: ...ttle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley coupler connection is loose Able Unable Able Unable 60 Throttle servo motor Throttle servo motor open or short circuit detected Motor is defective or ECU internal malfunction Able Unable Able Unable Fault code No Item Symptom Able unable to start Able unable to drive Er ...

Page 354: ...s not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation table 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 inner parts of the engin...

Page 355: ...01 appears on the odometer trip meter fuel reservoir trip meter stop watch LCD 6 Set the engine stop switch to OFF 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the odometer trip meter fuel reservoir trip meter stop watch LCD 01 70 To decrease the selected diagnostic code number press t...

Page 356: ...circuit in wire harness Defective intake air pressure sensor Malfunction in ECU 03 14 Intake air pressure sensor hose system malfunction clogged or detached hose Intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU 03 15 Throttle position sensor for throttle valves open or short circuit detected Throttle position sensor for throttle valves coupler con nection is...

Page 357: ...sensor Malfunction in ECU 02 24 No normal signal is received from the O2 sen sor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed O2 sensor 30 Latch up detected No normal signal is received from the lean angle sensor The vehicle has overturned Defective lean angle sensor Malfunction in ECU Improperly installed lean angle sensor 08 33 Open circuit de...

Page 358: ...t not appear on the meter Malfunction in ECU The program and data are not properly written on or read from the internal mem ory 59 Throttle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley cou pler connection is loose Open or short circuit in wire harness Defective throttle position sensor Improperly installed throttle posi...

Page 359: ...d atmospheric pres sure with the meter display value 03 Intake air pressure Displays intake air pressure Compare the actually mea sured atmospheric pres sure with the meter display value without cranking the engine 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured air temperature with the meter display value 06 Coolant temperature Displays the coolant te...

Page 360: ...y opened position 97 107 Check with throttle grip fully opened 15 Throttle position sensor for throttle cable pulley signal 2 Fully closed position 10 24 Check with throttle grip fully closed Fully opened position 95 109 Check with throttle grip fully opened 20 Sidestand switch Set ON OFF the sidestand switch with the transmis sion in gear Stand retracted ON Stand extended OFF 21 Neutral switch Sh...

Page 361: ...ns 03 is displayed To erase the history set the engine stop switch from to 63 Malfunction code reinstate for fault code No 24 only No malfunction code 00 Malfunction code exists Fault codes 24 If more than one code number is detected the dis play changes every two seconds to show all the detected code numbers When all code numbers are shown the display repeats To erase the history set the engine s...

Page 362: ...nel 36 Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 1 five times 37 Injector 2 Actuates the injector 2 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 2 five times 38 Injector 3 Actuates the inj...

Page 363: ... at one second intervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel injection system relay five times 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at one second intervals ON 2 sec onds OFF 3 seconds Il...

Page 364: ...e 2 Connections Cylinder identification sensor cou pler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the cylinder identifica tion sensor coupler...

Page 365: ...nsor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 92 Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code No 03 Intake air pressure sensor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Intake air pressure sensor coupler Main wire harness ECU coupler Check the cou...

Page 366: ...signal 2 Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor for throttle valves Check for looseness or pinch ing Check that the sensor is installed in the specified posi tion Turning the main switch to ON 2 Connections Throttle position sensor for throttle valves coupler Main wire harness ECU coupler Check the c...

Page 367: ...rvo motor potenti ometer circuit Execute the diagnostic mode Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check ...

Page 368: ...cuit Between ECU coupler and relay unit coupler Blue Yellow Blue Yellow Between relay unit coupler and sidestand switch coupler Blue Black Blue Black Between sidestand switch cou pler and engine ground Black Black 3 Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 8 81 Fault code No 20 Symptom When the main switch is turned to ON the atmospheric pressure senso...

Page 369: ...r Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 96 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Air temperature sensor coupler Main wire harness E...

Page 370: ...fective atmospheric pressure sen sor Execute the diagnostic mode Code No 02 Replace if defective Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 98 Fault code No 24 Symptom No normal signal is received from the O2 sensor Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Installed state of O2 sensor Check for looseness or pinchi...

Page 371: ... primary lead of the cylinder 1 ignition coil Diagnostic code No 30 Cylinder 1 ignition coil Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malf...

Page 372: ...be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 2 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 2 ignition coil coupler and ECU coupler Red Black Red Black Gray Red...

Page 373: ...pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 3 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler Red Black Red Black Orange Gree...

Page 374: ...out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 4 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU coupler main wire harness Red Black Red Black ...

Page 375: ...ed out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the fuel injector couplers 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between injector coupler and ECU coupler Red Blue Red Blue 1 Red Black Red Black 2 Green Black Green Bla...

Page 376: ...hat may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Reinstated automatically if a normal signal is received 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler Blue Blue Yellow Green Yellow Green Black Blue Black Blue 3 Defectiv...

Page 377: ...sor coupler and ECU coupler Blue Blue White Yellow White Yellow Black Blue Black Blue A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 95 B 1 Installed state of neutral switch Check for looseness or pinching B 2 Connections Neutral switch coupler Main wire harness ECU coupler Check the couplers for any pins that may...

Page 378: ...pler Red Red Between relay unit coupler and right handlebar switch coupler Red Black Red Black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code No 44 Symptom An error is detected while reading or writing on EEPROM CO adjustment value Diagnostic code No 60 EEPRO...

Page 379: ... short circuit in wire harness Repair or replace if there is an open or short circuit in the charging system s wiring Refer to CHARGING SYS TEM on page 8 11 Fault code No 50 Symptom Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement met...

Page 380: ...talled in the specified posi tion Turning the main switch to ON 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if ther...

Page 381: ...uit in wire harness Repair or replace if there is an open or short circuit Between throttle servo motor coupler and ECU coupler Yellow Red Yellow Red Light green Red Light green Red 4 Defective throttle servo motor Execute the diagnostic mode Code Nos 01 13 Replace the throttle body assembly if defective 5 Malfunction in ECU Replace the ECU Fault code No Er 1 Symptom No signals are received from t...

Page 382: ...ler Yellow Blue Yellow Blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the ...

Page 383: ...ter assembly coupler Check the couplers for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue 3 Malfunction i...

Page 384: ...FUEL PUMP SYSTEM 8 65 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 385: ... switch 4 Main fuse 8 Battery 9 Fuel injection system fuse 12 Starting circuit cut off relay 15 Fuel pump 19 ECU engine control unit 48 Multi function meter 58 Engine stop switch 79 Ignition fuse 88 Ground 89 Battery negative lead ...

Page 386: ...k the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 5 Check the starting circuit cut off relay Refer to CHECKING TH...

Page 387: ...FUEL PUMP SYSTEM 8 68 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to FUEL PUMP SYSTEM on page 8 65 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 388: ...IMMOBILIZER SYSTEM 8 69 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 389: ...EM 8 70 1 Main switch 4 Main fuse 5 Backup fuse 6 Immobilizer unit 8 Battery 19 ECU engine control unit 42 Immobilizer system indicator light 48 Multi function meter 79 Ignition fuse 88 Ground 89 Battery negative lead ...

Page 390: ... is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key for driving and to keep the code re regis tering key in a safe place ...

Page 391: ...lizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immo bilizer unit Standard key ECU Acces sory lock and key...

Page 392: ...egistration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 seconds insert the second standard key to be registered into the main switch NOTE If he immobilizer system indicator light stops flashing 5 seconds after the first standard k...

Page 393: ...on nor flashes NG OK NG OK NG OK a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first stan dard key is registered the second standard key cannot be registered 1 Check the fuses Main ignition and backup Refer to CHECKING THE F...

Page 394: ...eys and antennas 2 Immobilizer unit mal function 3 Key malfunction 1 Keep magnets metal objects and other immobilizer system keys away form the keys and antennas 2 Replace the main switch immobi lizer unit 3 Replace the key 52 IMMOBILIZER UNIT Codes between the key and immobilizer unit do not match 1 Signal received from other transponder failed to recognize code after ten consec utive attempts 2 ...

Page 395: ...tion 4 ECU failure The ECU or immobi lizer unit was replaced with a used unit from another vehicle 1 Register the code re registering key 2 Check the wire harness and con nector 3 Replace the main switch immobi lizer unit 4 Replace the ECU 55 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ...

Page 396: ...ELECTRICAL COMPONENTS 8 77 EAS27970 ELECTRICAL COMPONENTS ...

Page 397: ... 6 Starter relay 7 Battery 8 Main fuse 9 Neutral switch 10 Rear brake light switch 11 EXUP servo motor 12 Sidestand switch 13 O2 sensor 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Fuse box radiator fan motor signaling sys tem ignition ETV backup 21 Fuse box headlight ...

Page 398: ...ELECTRICAL COMPONENTS 8 79 ...

Page 399: ...urn signal relay 7 ECU engine control unit 8 Lean angle sensor 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 13 Throttle position sensor for throttle valves 14 Cylinder identification sensor 15 Radiator fan motor relay 16 Headlight relay dimmer 17 Headlight relay on off ...

Page 400: ...ELECTRICAL COMPONENTS 8 81 EAS27980 CHECKING THE SWITCHES ...

Page 401: ... 1 Main switch 2 Horn switch 3 Dimmer switch 4 Turn signal switch 5 Clutch switch 6 Sidestand switch 7 Engine stop switch 8 Front brake light switch 9 Start switch 10 Oil level switch 11 Neutral switch 12 Rear brake light switch ...

Page 402: ...o 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a ...

Page 403: ... CAUTION ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly it with ...

Page 404: ...mmediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Side cowlings Passenger seat Rider seat EAS28030 CHECKI...

Page 405: ...the charge state of the battery by measuring the specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Battery leads from the battery terminals CAUTION ECA13640 First disconnect the negative battery lead 1 and then positive battery lead 2 3 Re...

Page 406: ...current voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charged and AMP meter to the battery and start charging NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged c Make sure that the current is higher tha...

Page 407: ...ect properly 9 Lubricate Battery terminals 10 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out...

Page 408: ...y terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negativ...

Page 409: ...e 1 Negative tester probe Ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Black Yellow 2 No continuity Positive tester probe Black Yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue Yellow 3 No continuity Positive tester probe Blue Yellow 3 Negative teste...

Page 410: ...oil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the ignition coil leads from the ignition coil b Connect the pocket tester Ω 1k to the ignition coil as shown c Measure the secondary coil resistance 3 Check Ignition spark gap Out of specification Replace Primary coil resistance 0 85 1 15 Ω at 20 C 68 F Pocket tester 9089...

Page 411: ...ankshaft position sensor resistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Minimum ignition spark gap 6 0 mm 0 24 in Ignition checker 90890 06754 ...

Page 412: ...e sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the rectifier regulator 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHEC...

Page 413: ... the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the specified horn sound is obtained EAS28190 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Charging voltage 14 V at 5000 r min Pocket tester 90890 03112 Ana...

Page 414: ...sensor coupler wire harness side as shown Oil level switch Maximum level position resis tance 484 536 Ω at 20 C 68 F Minimum level position resis tance 114 126 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Maximum level position A Positive tester probe Connector white 1 Negative tester probe Body earth 2 Minimum level position B Positive tester probe Connector white 1 Ne...

Page 415: ...e the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor 1 as shown b Immerse the coolant temperature sensor in a container filled with coolant 2...

Page 416: ...istance 3 Install Throttle position sensor for throttle cable pulley NOTE When installing the throttle position sensor for throttle cable pulley adjust its angle properly Refer to ADJUSTING THE THROTTLE POSI TION SENSOR FOR THROTTLE CABLE PULLEY on page 7 7 EAS28300 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Remove Throttle position sensor for throttle valves from the throttle bod...

Page 417: ...tester Ω 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure sensor output volt age Out of specification Replace a Connect the pocket tester DC 20 V to the atmospheric pressure sensor coupler wire harness side as shown b Set the main switch to ON c Measure the...

Page 418: ...ss side as shown b Set the main switch to ON c Measure the intake air pressure sensor output voltage EAS28420 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is d...

Page 419: ...take air temperature sensor resistance 3 Install Intake air temperature sensor Intake air pressure sensor resistance 2 21 2 69 kΩ at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown White 1 Negative tester probe Black Blue 2 Intake air temperature sensor bolt 1 2 Nm 0 12 m kg 0 87 ft lb ...

Page 420: ...ELECTRICAL COMPONENTS 8 101 ...

Page 421: ...LING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 422: ...minated fuel 2 Fuel pump Faulty fuel pump Faulty 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 damaged insula...

Page 423: ...ift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improper...

Page 424: ... fluid level EAS28650 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 assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn ...

Page 425: ... does not come on Too many electrical accessories Incorrect connection Tail brake light bulb burnt out Faulty battery Incorrectly adjusted rear brake light switch Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Tur...

Page 426: ...l switch 56 Right handlebar switch 57 Front brake light switch 58 Engine stop switch 59 Start switch 60 Turn signal relay 61 Left handlebar switch 62 Dimmer switch 63 Horn switch 64 Clutch switch 65 Turn signal switch 66 Horn 67 Front left turn signal light 68 Front right turn signal light 69 Rear left turn signal light 70 Rear right turn signal light 71 Headlight 72 Auxiliary light 73 Ground cord...

Page 427: ...A B B L R B B L R B B L B B R L L W R B L W R Sb W B Y Sb L Y L B R W L Y L W B R W Br R W R B Dg Y Br W R Y Ch L Y B B Y Br Dg Y Br W R Y Ch L Y B B Y Br R OFF RUN FREE PUSH R N L Br W Br HI LO OFF ON B B Br Br R B R Y B L Y L Y L B L B B Y B Y L W Sb W Sb Sb L W Y G Y Br W Br W Dg Ch Y Y R L L Y L W L W R G Y L Lg W Y B L W R G Y L Lg B RY B Gy R O R BO G W BBr R L Gy G B L R W Gy R O R B O G W ...

Page 428: ...SS D B HEADLIGHT SUB WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 6 2 3 1 5 79 82 80 81 83 85 78 87 86 84 77 75 61 63 65 64 66 67 68 69 70 54 54 53 52 35 36 37 38 39 40 33 32 51 50 49 48 47 46 45 44 43 42 41 55 62 76 74 73 71 72 71 72 88 89 7 4 8 9 10 11 56 57 58 59 12 14 13 60 15 17 18 16 34 20 24 24 24 24 25 26 19 27 28 29 30 31 21 22 23 YZFR1W 2007 WIRING DIAGRAM YZFR1W 2007 SCHEMA DE CABLAGE ...

Page 429: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 ...

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