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Yamaha YZFR1Y(C) 2009, Service Manual

The Yamaha YZFR1Y(C) 2009 is a high-performance sports bike, offering an adrenaline-pumping riding experience. Ensure optimal performance and longevity of this remarkable machine by downloading the free service manual from manualshive.com, where you can find a comprehensive user manual available for download.

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FRONT FORK

4-69

TIP

Use the side of the rod holder that is marked 
“B”.

j.

Remove the rod puller and rod puller 
attachment.

k. Install the nut “1” all the way onto the 

damper rod assembly.

l.

Install the damper adjusting valve spring, 
the damper adjusting valve and the damper 
adjusting rod.

m. Install the washer and cap bolt, and then 

finger tighten the cap bolt.

n. Hold the nut and tighten the spring preload 

adjusting bolt “2” into the cap bolt to specifi-
cation.

WARNING

EWA14B1011

Always use a new cap bolt O-ring.

ECA14B1009

When tightening the spring preload adjust-
ing bolt “2” into the cap bolt, be sure not to 
break the projections “a” on the cap bolt 
collar “3”.

TIP

Hold the nut “1” using a proper tool that has a 
thickness “b” of 4.0 mm (0.16 in) or less.

o. Remove the rod holder and fork spring 

compressor.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

16. Install:

• Cap bolt

(to the outer tube)

TIP

• Temporarily tighten the cap bolt.
• When to tighten the cap bolt to the specified 

torque is after installing the front fork leg to 
the vehicle and tightening the lower bracket 
pinch bolts.

EAS14B1009

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.

Rod puller

90890-01437

Universal damping rod bleeding 
tool set

YM-A8703

Rod puller attachment (M10)

90890-01436

Universal damping rod bleeding 
tool set

YM-A8703

Fork spring compressor

90890-01441
YM-01441

Rod holder

90890-01434

Damper rod holder double 
ended

YM-01434

Nut and cap bolt

25 Nm (2.5 m·kgf, 18 ft·lbf)

Summary of Contents for YZFR1Y(C) 2009

Page 1: ...SERVICE MANUAL YZFR1Y C 14B 28197 10 LIT 11616 22 78 2009 ...

Page 2: ...Yamaha Motor Corporation U S A First edition December 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Cor poration U S A is expressly prohibited Printed in U S A P N LIT 11616 22 78 ...

Page 3: ...er 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 TIP This Service Manual con...

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

Page 5: ...N SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOC TITE Engine oil Replace the part with a new one ...

Page 6: ......

Page 7: ...1 2 3 4 5 6 7 8 9 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 8: ......

Page 9: ...led Throttle YCC I Yamaha Chip Controlled Intake 1 4 INSTRUMENT FUNCTIONS 1 8 IMPORTANT INFORMATION 1 15 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 15 REPLACEMENT PARTS 1 15 GASKETS OIL SEALS AND O RINGS 1 15 LOCK WASHERS PLATES AND COTTER PINS 1 15 BEARINGS AND OIL SEALS 1 16 CIRCLIPS 1 16 CHECKING THE CONNECTIONS 1 17 HANDLING THE ELECTRONIC PARTS 1 18 SPECIAL TOOLS 1 19 ...

Page 10: ...FICATION 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 seat rail reinforcement under the passenger seat This information will be needed to order spare parts ...

Page 11: ...st gases increase it 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 inj...

Page 12: ...sor accelerator position sensor coolant temperature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor air temperature sensor speed sensor and O2 sensor enable the ECU to deter mine the injection duration The injection timing is determined through the signals from the crank shaft position sensor As a result the ...

Page 13: ...lume of intake air for 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 ...

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

Page 16: ...tmospheric pressure sensor 9 Accelerator position two signals 10 Throttle position two signals 11 Engine revolution 12 Vehicle speed 13 Coolant temperature 14 Neutral In gear 15 Atmospheric pressure 16 Throttle servo motor 17 ECU engine control unit 18 Base map 19 Idle speed control 20 Calculated throttle valve opening angle 21 Base map 22 Air funnel position Calculation value 23 Intake funnel ser...

Page 17: ...ghtness shift timing indicator light and throttle opening position display control mode TIP Be sure to turn the key to ON before using the SELECT and RESET buttons To switch the speedometer and odometer tripmeter fuel consumption 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 ...

Page 18: ...CT button to stop the stopwatch and display the total elapsed time Split time history The split time history displays up to 20 stored split times The split time history can be dis played either in reverse chronological order or by speed 1 Push the SELECT button for at least one second to select the reverse chronological order mode L20 displays on the stop watch Push the SELECT button again to sele...

Page 19: ...ESET button for at least one second If you do not reset the fuel reserve tripmeter manually it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km 3 mi Instantaneous fuel consumption mode The instantaneous fuel consumption display can be set to either km L L 100 km or MPG When the display is set to km L the dis tance that can be traveled on 1 0 ...

Page 20: ...t one second TIP After resetting an average fuel consumption display _ _ _ is shown for that display until the vehicle has traveled 1 km 0 6 mi Transmission gear display This display shows the selected gear The neutral position is indicated by and by the neutral indicator light Throttle opening position display The throttle opening position display shows how much the throttle is being opened The n...

Page 21: ...e coolant temperature is automatically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed before the temper ature Self diagnosis device This model is equipped with a self diagnosis device for various electrical circuits If a problem is detected in any of those circuits the engine trouble warn...

Page 22: ... to confirm the selected brightness level The control mode changes to the shift timing indicator light activity function To set the shift timing indicator light activity function 1 Push the RESET button to select one of the following indicator light activity settings The indicator light stays on when acti vated This setting is selected when the indicator light stays on The indicator light flashes ...

Page 23: ...ter or tripmeter mode D mode drive mode D mode is an electronically controlled engine performance system with three mode selec tions STD A and B Push the drive mode switch MODE to switch between modes TIP Before using D mode make sure you under stand its operation along with the operation of the drive mode switch MODE Mode STD Mode STD is suitable for various riding condi tions This mode allows th...

Page 24: ... 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 25: ...ed grease Oil bearings liberally when installing if appro priate 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 opposi...

Page 26: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP 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 m...

Page 27: ...ectricity and it s voltage is very high and electronic parts is very sensitive It has possibility that inside small parts of elec tronic parts is destroyed by static electricity Do not touch and do not make it dirty When you disconnect electronic parts from wire harness always turn off main switch If you disconnect above condition it may gives damages to electronic parts ...

Page 28: ...depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 76 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6...

Page 29: ...per rod holder 90890 01506 YM 01506 4 64 4 66 Oil filter wrench 90890 01426 YU 38411 3 27 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 63 4 69 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 67 4 69 Tool name Tool No Illustration Reference pages YM A8703 ...

Page 30: ...ing compressor 90890 01441 YM 01441 4 63 4 69 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 66 4 67 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 9 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Tool name Tool No Illustration Reference pages YM A8703 YU 44456 ...

Page 31: ...pressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 30 5 36 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 14 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 14 Universal clutch holder 90890 04086 YM 91042 5 63 5 67 Tool name Tool No Illustration Reference pages ...

Page 32: ...0 mm YM 04098 5 32 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 32 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 32 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 32 Ignition checker 90890 06754 Opama pet 4000 spark checker YU 34487 8 116 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 10 Tool name ...

Page 33: ...ressure adapter H 90890 03139 3 29 Pressure gauge 90890 03153 YU 03153 3 29 7 18 Fuel pressure adapter 90890 03176 YM 03176 7 18 Fuel injector pressure adapter 90890 03210 YU 03210 7 18 Camshaft wrench 90890 04143 YM 04143 5 18 5 21 Ring nut wrench 90890 01507 YM 01507 4 81 4 83 Tool name Tool No Illustration Reference pages ...

Page 34: ...eave holder 90890 01701 Primary clutch holder YS 01880 A 5 38 5 41 5 42 5 44 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 17 5 48 8 107 8 108 8 109 8 113 8 114 8 115 8 116 8 117 8 118 8 119 8 120 8 121 8 122 8 123 8 124 8 125 8 126 8 127 8 128 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 8 124 8 126 Tool name Tool No Illustration Reference pages ...

Page 35: ...sor 3P 90890 03208 YU 03208 8 121 8 125 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 117 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 8 124 8 126 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 24 5 39 5 45 5 73 Tool name Tool No Illustration Reference pages ...

Page 36: ...SPECIAL TOOLS 1 27 ...

Page 37: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 26 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 45 CABLE ROUTING 2 49 ...

Page 38: ...ifornia Dimensions Overall length 2070 mm 81 5 in Overall width 715 mm 28 1 in Overall height 1130 mm 44 5 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel 206 kg 454 lb Maximum load 189 kg 417 lb ...

Page 39: ... 4 84 US qt 4 03 Imp qt Without oil filter cartridge replacement 3 73 L 3 94 US qt 3 28 Imp qt With oil filter cartridge replacement 3 93 L 4 15 US qt 3 46 Imp qt Oil filter Oil filter type Formed Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 090 0 190 mm 0 0035 0 0075 in Limi...

Page 40: ...3 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 25 500 25 521 mm 1 0039 1 0048 in Camshaft journal diameter 25 459 25 472 mm 1 0023 1 0028 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Intake A 37 350 37 450 mm 1 4705 1 4744 in Limit 37 250 mm 1 4665 in Intake B 28 034 28 134 mm 1 ...

Page 41: ...in Limit 1 80 mm 0 07 in Valve margin thickness D intake 1 35 1 75 mm 0 0532 0 0689 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 960 mm 0 1953 in Valve stem diameter exhaust 4 460 4 475 mm 0 1756 0 1762 in Limit 4 425 mm 0 1742 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0 1973 in Limit 5 050 mm...

Page 42: ... 72 kgf 41 59 47 88 lbf Spring tilt limit intake 2 5 1 7 mm 0 067 in Spring tilt limit exhaust 2 5 1 7 mm 0 067 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 150 mm 0 0059 in Pist...

Page 43: ... mm 0 0039 0 0157 in Connecting rod Crankshaft pin to big end bearing clearance 0 034 0 058 mm 0 0013 0 0023 in Limit 0 09 mm 0 0035 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Width A 59 40 60 10 mm 2 339 2 366 in Width B 301 80 303 00 mm 11 88 11 93 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Journal oil clearance 0 004 0 039 ...

Page 44: ...ar ratio 1st 38 15 2 533 2nd 33 16 2 063 3rd 37 21 1 762 4th 35 23 1 522 5th 30 22 1 364 6th 33 26 1 269 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0 100 mm 0 0039 in Shift fork L thickness 5 795 5 868 mm 0 2281 0 2310 in Shift fork C thickness 5 795 5 868 mm ...

Page 45: ...57 3 71 V at 101 32 kPa Intake air pressure sensor output voltage 3 57 3 71 V at 101 32 kPa Intake air temperature sensor resistance 5 4 6 6 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F Air induction system Reed valve bending limit 0 4 mm 0 016 in Solenoid resistance 18 22 Ω at 20 C 68 F Idling condition Engine idling speed 1150 1250 r min CO 2 6 3 6 Intake vacuum 1 3 4 24 0 kPa 180 mmHg 7 1 inHg Intake...

Page 46: ...t 1 0 mm 0 04 in Rear tire Type Tubeless Size 190 55 ZR17M C 75W Manufacturer model DUNLOP D210 Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42 psi 2 90 bar Loading condition 90 189 kg 198 417 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42 psi 2...

Page 47: ...8 18 mm 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 27 0 Center to lock angle right 27 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fork spring free length 271 5 mm 10 69 in Limit 266 1 mm 10 48 in Collar length 118 4 mm 4 66 in Installed length 262 0 mm 10 3...

Page 48: ...ximum 0 Rebound damping adjusting positions Minimum 20 Standard 15 Maximum 3 Compression damping setting for fast compression damping Minimum 4 Standard 3 Maximum 0 Compression damping setting for slow compression damping Minimum 20 Standard 9 Maximum 1 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive chain Type manufacturer 50VAZ ...

Page 49: ...ltage 14 2 14 8 V Rectifier regulator input voltage above 14 V at 5000 r min Rectifier capacity 50 0 A Lean angle sensor Lean angle sensor output voltage Less than 45 0 4 1 4 V More than 45 3 7 4 4 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 31 Manufacturer GS YUASA Ten hour rate amperage 0 90 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 ...

Page 50: ...y Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pcs Maximum amperage 3 0 A Coil resistance 1 07 1 11 Ω at 20 C 68 F Turn signal relay Relay type Full transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Ω Minimum level position resistance 114 126 Ω Fuel gauge Fuel sender resistance 14 141 Ω at 20 C 68 F Speed sensor ...

Page 51: ... system fuse 7 5 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Fuel injection system fuse 15 0 A Steering damper fuse 7 5 A Backup fuse 7 5 A ETV Electronic Throttle Valve fuse 7 5 A Spare fuse 20 0 A Spare fuse 15 0 A 2 Spare fuse 7 5 A ...

Page 52: ...l 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 kgf ft lbf 10 mm 6 mm 6 0 6...

Page 53: ... kgf 7 2 ft lbf Water pump inlet pipe bolt water pump side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water hose clamp 6 2 Nm 0 2 m kgf 1 4 ft lbf Oil water pump driven sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil water pump assembly bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Thermostat housing cover nut M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Therm...

Page 54: ... M8 2 23 Nm 2 3 m kgf 17 ft lbf Muffler cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Exhaust chamber protector bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Muffler pipe cover bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Crankcase stud bolt M10 10 8 Nm 0 8 m kgf 5 8 ft lbf Crankcase bolt main journal M9 10 See TIP l 100 mm 3 94 in Crankcase bolt M8 8 24 Nm 2 4 m kgf 17 ft lbf l 60 mm 2 36 in Crankcase bolt M8 2 24 Nm ...

Page 55: ...r gear bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch holder bolt M6 3 14 Nm 1 4 m kgf 10 ft lbf Clutch boss nut M20 1 115 Nm 11 5 m kgf 85 ft lbf Stake Clutch spring bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Drive sprocket nut M22 1 85 Nm 8 5 m kgf 61 ft lbf Stake Bearing housing bolt M6 3 12 Nm 1 2 m kgf 8 7 ft lbf Shift drum retainer bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Stopper screw M8 1 22 Nm...

Page 56: ...urface 2 Tighten the bolt to 20 Nm 2 0 m kgf 14 ft lbf 3 Retighten the bolt further to reach the specified angle of 145 155 TIP Crankcase bolt main journal 1 Lubricate the bolts thread mating surfaces and washers with engine oil 2 First tighten the bolts to approximately 30 Nm 3 0 m kgf 22 ft lbf with a torque wrench 3 Loosen all the bolts one by one following the tightening order and then tighten...

Page 57: ...ft lbf Rear shock absorber assembly lower nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly and bracket nut M10 1 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly bracket and frame nut M16 1 92 Nm 9 2 m kgf 66 ft lbf Drive chain guide bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Locknut drive chain adjusting nut M8 2 16 Nm 1 6 m kgf...

Page 58: ...m kgf 6 5 ft lbf Rear fuel tank bracket and rear frame bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank and rear fuel tank bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank upper cover and frame bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank upper cover and fuel tank bolt rear M5 2 4 Nm 0 4 m kgf 2 9 ft lbf Fuel tank upper cover and fuel tank bolt side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank side...

Page 59: ...hem by adding the external force by hand or with a plastic hammer etc If the end face of the axle is not parallel to the end face of the fork align them so that one point of the axle circumference is positioned on the end face of the fork Front wheel axle pinch bolt M8 4 21 Nm 2 1 m kgf 15 ft lbf See TIP Rider footrest bolt M8 4 28 Nm 2 8 m kgf 20 ft lbf Passenger footrest bolt M8 4 28 Nm 2 8 m kg...

Page 60: ...n 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 kgf 15 ft lbf without performing temporary tightening ...

Page 61: ...d washer Crankshaft sprocket bolt thread Balancer gear press fitting surface O rings coolant pipe Oil pump rotors inner and outer Shell Alvania EP Grease Oil cooler bolt thread and washer O ring oil nozzle O ring main gallery plug Idler gear and idler gear shaft Starter clutch assembly Starter clutch gear thrust surface Primary driven gear Clutch boss nut thread and bearing surface Pull rod Oil wa...

Page 62: ...UBRICATION POINTS AND LUBRICANT TYPES 2 25 Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Crankcase cover lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant ...

Page 63: ... and rear shock absorber spacer Swingarm pivot shaft Swingarm pivot shaft bearings Swingarm dust cover lips Relay arm connecting arm and rear shock absorber oil seal lips Seat lock lever pivoting point Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Sidestand bracket and sidestand bolt Shift shaft joint ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 65: ...Oil pump 3 Relief valve 4 Oil cooler 5 Sub gallery 6 Oil filter cartridge 7 Main gallery 8 Mission shower 9 Drive axle 10 Main axle 11 Shift fork upper 12 Crankshaft 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil filter cartridge 5 Oil level switch ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 69: ...TION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Crankshaft 5 Balancer shaft 6 Oil cooler 7 Relief valve 8 Oil pipe 9 Oil strainer 10 Oil water pump assembly ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil level switch 3 Oil strainer 4 Oil pipe 5 Relief valve 6 Oil cooler ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil water pump assembly ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Oil delivery pipe 2 3 Drive axle ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Shift fork guide bar 2 Shift fork C 3 Shift drum assembly 4 Shift fork R 5 Drive axle 6 Shift fork L ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil nozzle 5 Crankshaft ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Balancer shaft 2 Crankshaft ...

Page 82: ...COOLING SYSTEM DIAGRAMS 2 45 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 83: ...COOLING SYSTEM DIAGRAMS 2 46 1 Oil water pump assembly 2 Radiator 3 Radiator fan 4 Thermostat 5 Oil cooler ...

Page 84: ...COOLING SYSTEM DIAGRAMS 2 47 ...

Page 85: ...COOLING SYSTEM DIAGRAMS 2 48 1 Radiator cap 2 Radiator 3 Radiator fan 4 Oil cooler ...

Page 86: ...CABLE ROUTING 2 49 EAS20430 CABLE ROUTING ...

Page 87: ...y side D Route the auxiliary light lead under the front intake air duct and connect E To the main harness F To the turn signal G Cut off the excess end of the clamp H When clamping the headlight sub wire har ness it should not be sagged Face the end of the clamp to front I Route the headlight lead toward the front of the meter bracket and connect J To the meter K Fix the turn signal relay by inser...

Page 88: ...CABLE ROUTING 2 51 ...

Page 89: ...h lead under the brake hose G Route the right handlebar switch lead above the metal fitting on the brake hose H Route the throttle cable above the under bracket inside of the front fork and under the brake fluid reservoir hose I Fasten the plastic band inside of the front fork Fasten the band at position of the main switch lead white left handlebar switch lead blue and steering damper lead white J...

Page 90: ...CABLE ROUTING 2 53 ...

Page 91: ...lit D Clamp the clutch cable and oil cooler outlet hose at the protector rivet ring of the clutch cable E Clamp the right radiator fan motor lead right handlebar switch lead main harness and AC magneto lead under the rectifier regulator bracket rib and face the end of the clamp down F Clamp the right radiator fan motor lead right handlebar switch lead and AC mag neto lead under the rectifier regul...

Page 92: ...CABLE ROUTING 2 55 ...

Page 93: ...ition coil lead 2 Crankshaft position sensor lead 3 Rear brake light switch lead 4 O2 sensor lead A Route the rear brake light switch lead out side of the O2 sensor lead and push it to the occluding surface of the clutch cover ...

Page 94: ...CABLE ROUTING 2 57 ...

Page 95: ...ar brake caliper bracket and torque receptor groove of the swing arm G Make sure to pass the brake hose through the brake hose holder H Face the clamp in the direction shown in the illustration I Make sure to bend the cotter pin It can be bent in the same direction J Positioning of the exhaust chamber cover and exhaust chamber upper cover is shown in the illustration K Projection of the right foot...

Page 96: ...CABLE ROUTING 2 59 ...

Page 97: ...le position sensor for throttle valves D Connect the left handlebar switch lead main switch lead steering damper lead and left radiator fan motor lead and put the connector cover E Clamp the left handlebar switch lead main switch lead and steering damper lead under the main harness Ratchet of the clamp can face in any direction F To the turn signal G To the intake air temperature sensor head light...

Page 98: ...CABLE ROUTING 2 61 ...

Page 99: ...rocket cover F 30 50 mm 1 18 1 97 in G Route the fuel tank breather hose fuel tank overflow hose and coolant reservoir breather hose inner side of the water pump bypass hose then through the binding clamp on the sidestand switch and to the outside of the under cover End of the hoses can face in any direction H To the oil level switch I Route the AC magneto lead through inner side of the coolant re...

Page 100: ...CABLE ROUTING 2 63 ...

Page 101: ... tery negative lead I Clamp at position of the starter motor lead white and fuel pump branch lead purple Do not cut the end and face the clamp to the back J Install with the ground lead at the bottom and the battery negative lead on the top Install the rivet of the each lead facing up Angle of installing each lead is shown in the illustration K Route the canister purge hose under the wire harness ...

Page 102: ...CABLE ROUTING 2 65 ...

Page 103: ...e left of the battery box 2 boss E After passing the tail brake light lead license plate light lead right turn signal light lead and left turn signal light lead through the guide of the battery box 2 route them between the ribs F When installing the seal align it to the push pin trace mark of the rear frame both left right G Align the positioning tape of the battery negative lead to the clamp H Fa...

Page 104: ...CABLE ROUTING 2 67 ...

Page 105: ...w hose with its yellow paint facing front of the vehicle I Install the fuel tank overflow hose and fuel tank breather hose with the clamp opening facing down J Fuel pump side K Insert the connector until 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 equival...

Page 106: ...CABLE ROUTING 2 69 ...

Page 107: ...5 Injector 1 coupler 16 Injector 2 coupler 17 Injector 3 coupler 18 Injector 4 coupler 19 Cap A Checker color orange B Checker color black C Rotate the clip to the right of the vehicle D Adjust top edge of the clip to top edge of the paint E Make sure the intake air pressure sensor is touching against the stopper and install it horizontally F After installing the intake air pressure sen sor do not...

Page 108: ...CABLE ROUTING 2 71 ...

Page 109: ...b wire harness Position the plastic locking tie as shown in the illustra tion F Position the sub wire harness under the bearing surface of the bolt so that it is not pinched G When installing the air filter case the sub wire harness should not be pinched H Make sure the grommet is not pinched I When installing the cap case assembly the sub wire harness should not be pinched J The indicated line is...

Page 110: ...CABLE ROUTING 2 73 ...

Page 111: ...E REAR BRAKE PADS 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 16 CHECKING THE FRONT BRAKE HOSES 3 17 CHECKING THE REAR BRAKE HOSE 3 17 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM OPERATION 3 19 ADJUSTING THE DRIVE CHAIN SLACK 3 19 LUBRICATING THE DRIVE CHAIN 3 20 CHECKING AND ADJUSTING THE STEERING HEAD 3 20 CHECKING THE STEERING DAMPER 3 ...

Page 112: ...32 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 32 CHECKING AND LUBRICATING THE CABLES 3 32 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 32 LUBRICATING THE REAR SUSPENSION 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULBS 3 33 ADJUSTING THE HEADLIGHT BEAMS 3 34 ...

Page 113: ......

Page 114: ...METER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check an...

Page 115: ...th operation Replace if necessary 9 Swingarm pivot bearings Check operation and for excessive play Lubricate with lithium soap based grease Every 30000 mi 50000 km 10 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 500 mi 800 km and after washing the motorcycle or riding in the rain 11 Steering bearings Check b...

Page 116: ...s and if cracked or damaged 20 Front fork Check operation and for oil leakage Replace if necessary 21 Shock absorber assembly Check operation and for oil leakage Replace if necessary 22 Rear suspension link pivots Check operation Correct if necessary 23 Engine oil Change warm engine before draining 24 Engine oil filter cartridge Replace 25 Cooling system Check hoses for cracks or damage Replace if...

Page 117: ...el tank breather hose is routed correctly 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1114 CHECKING THE FUEL LINE Secondary injector 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Fuel tank Refer to FUEL TANK on page 7 1 3 Check Fuel hose 1 Cracks damage Replace Loose connection Connect properly TIP Before re...

Page 118: ... thickness gauge Out of specification Regap 11 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 12 Install Ignition coil 13 Install Radiator fan Radiator Refer to RADIATOR on page 6 1 14 Install Air filter case Refer to AIR FILTER CASE on page 7 5 15 Install Fuel tank Refer to FUEL TANK on page 7 1 16 Install Lower cowlings Side cowlings Refer to GENE...

Page 119: ...ickup rotor cover 1 1 Pickup rotor cover 2 2 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise and align the pickup rotor K mark a and crankcase occluding surface b At this time make sure the intake cam shaft sprocket punch mark c and cylinder head occluding surface d and exhaust camshaft sprocket punch mark e and cyl inder head occluding surface f are aligned I...

Page 120: ...lve clearance 2 and 4 with a thickness gauge TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence 5 Remove Camshafts TIP Refer to CAMSHAFTS on page 5 13 When removing the timing chain and cam shafts fasten the timing chain with a wire to retrieve it if it falls into the crankcase 6 Adjust Valve clearance Thickness gauge 90890 031...

Page 121: ...the original c Round off the original valve pad number according to the following table EXAMPLE Original valve pad number 148 thickness 1 48 mm 0 058 in Rounded value 150 d Locate the rounded number of the original valve pad and the measured valve clear ance in the valve pad selection table The point where the column and row intersect is the new valve pad number TIP The new valve pad number is onl...

Page 122: ...e specified clear ance is obtained 7 Install All removed parts TIP For installation reverse the removal proce dure EAS20571 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hoses Air induction system Exhaust system Breather hoses Checking the throttle body synchronizatio...

Page 123: ...perate properly TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg Adjust only 2 1 6 kPa 12 mmHg 0 49 inHg higher 2 Stop the engine and remove the measuring equ...

Page 124: ...er seat Refer to GENERAL CHASSIS on page 4 1 3 Remove Side cowlings Refer to GENERAL CHASSIS on page 4 1 4 Remove Rear brake master cylinder Refer to REAR BRAKE on page 4 43 5 Remove Radiator lower bracket Refer to RADIATOR on page 6 1 6 Check Exhaust pipe 1 Exhaust chamber 2 Mufflers 3 Cracks damage Replace Gaskets 4 Exhaust gas leaks Replace 7 Check Tightening torque Exhaust pipe nut 20 Nm 2 0 m...

Page 125: ... filter seal Damage Replace TIP Replace the air filter element every 40000 km 24000 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 5 Install Air filter element Refer to AIR FILTER CASE on page 7 5 6 Install Air filter case cover Refer to AIR FILTER CASE on page 7 5 ECA14401 Never operate the engine without the air fil ter element instal...

Page 126: ... THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check the brake system Refer to FRONT BRAKE on page 4 30 and REAR BRAKE on page 4 43 TIP Drive on the dry road operate the front and rear brakes separately and check to see if the brakes are operating fully EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand ...

Page 127: ...BRAKE 1 Adjust Brake lever position distance a from the throttle grip to the brake lever TIP While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position WARNING EWA13060 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake l...

Page 128: ...1 to specification WARNING EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ECA13510 After adjusting the brake pedal position make sure there is no brake drag 3 Adjust Rear brake light swit...

Page 129: ...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 plastic hose 1 tightly to the bleed screw 2 TIP Bleeding order of the front hydraulic brake sys tem is the fo...

Page 130: ...cle upright and apply the brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to FRONT BRAKE on page 4 30 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 leak...

Page 131: ...ous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear 290 kPa 2 90 kgf cm 42 psi 2 90 bar Loading condition 90 189 kg 198 417 lb Front 250 kPa 2 50 kgf cm 36 psi 2 50 bar Rear...

Page 132: ...lies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 20 and CHECKING THE REAR WHEEL on page 4 27 EAS14B1090 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM on page 4 79 2 Check Swingarm excessive play Refer to SWINGARM on page 4 79 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK T...

Page 133: ...when the vehicle is used in dusty areas This vehicle has a drive chain with small rub ber O rings between each side plate Steam cleaning high pressure washing certain sol vents and the use of a coarse brush can dam age these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O rin...

Page 134: ...letely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 71 e Install the rubber washer 7 f Install the upper ring nut 8 g Finger tigh...

Page 135: ... shift rod length a 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position c Tighten both locknuts d Make sure the installed shift rod length is within specification EAS14B1094 CHECKING THE SIDESTAND 1 Stand the vehicle on a level surface WARNING EWA13...

Page 136: ...f the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 60 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA14B1029 Securely support the motorcycle so that there is no danger of it falling over Spring preload WARNING EWA14B1026 Always adjust both front fork legs evenly Uneven adjustment can result in poo...

Page 137: ...BSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload adjusting posi tions Minimum 0 Standard 2 Maximum 5 Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 25 click s out Standard 12 click s out Maximum 1 click s...

Page 138: ...ustment positions 1 Adjust Compression damping for fast compres sion damping a Turn the adjusting bolt 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 16 turn s out Standard 8 turn s out Maximum 0 turn s out With the adjusting screw fully turned in Direction a...

Page 139: ...ne warm it up for several minutes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maxi mum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Minimum 4 turn s out Standard 3 turn s out Maximum 0 turn s out With the adjusting screw fully turned in Direction a Compression damping is increased ...

Page 140: ...el 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 Refer to GENERAL CHASSIS on page 4 1 4 Remove Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 5 Drain Engine oil completely from the crankcase 6 If th...

Page 141: ...NE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 2 Start the engine warm it up for several minutes and then turn it off ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Re...

Page 142: ...ailable soft water may be used 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4 1 2 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler inlet hose 4 Oi...

Page 143: ...ator 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 follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any re...

Page 144: ... 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 types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maximum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up f...

Page 145: ...NG EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS20630 ADJUSTING THE THROTTLE ...

Page 146: ...MPONENTS on page 8 101 EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove Headlight bulb cover 1 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb holder 1 Headlight bulb 2 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 4 Install Headli...

Page 147: ...EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left headlight Right headlight Direction a Headlight beam is raised Direction b Headlight beam is lowered Direction a Headlight beam m...

Page 148: ...PERIODIC MAINTENANCE 3 35 ...

Page 149: ...THE INTAKE AIR DUCT COVERS 4 14 INSTALLING THE AIR INTAKE DUCTS 4 14 INSTALLING THE REAR VIEW MIRRORS 4 14 REMOVING THE WINDSHIELD 4 15 INSTALLING THE WINDSHIELD 4 15 INSTALLING THE MIRROR FITTING PLATES 4 15 REMOVING THE UPPER TAIL COVER 4 15 INSTALLING THE UPPER TAIL COVER 4 16 INSTALLING THE TAIL BRAKE LIGHT 4 16 ADJUSTING THE RIDER FOOTRESTS 4 16 FRONT WHEEL 4 18 REMOVING THE FRONT WHEEL 4 20 ...

Page 150: ...INDER 4 52 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 53 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 53 HANDLEBARS 4 55 REMOVING THE HANDLEBAR 4 57 CHECKING THE HANDLEBARS 4 57 INSTALLING THE HANDLEBARS 4 57 FRONT FORK 4 60 REMOVING THE FRONT FORK LEGS 4 63 DISASSEMBLING THE FRONT FORK LEGS 4 63 CHECKING THE FRONT FORK LEGS 4 64 ASSEMBLING THE FRONT FORK LEGS 4 65 INSTALLING THE FRONT FORK LEGS 4...

Page 151: ...NGARM 4 82 INSTALLING THE SWINGARM 4 82 CHAIN DRIVE 4 84 REMOVING THE DRIVE CHAIN 4 85 CHECKING THE DRIVE CHAIN 4 85 CHECKING THE DRIVE SPROCKET 4 86 CHECKING THE REAR WHEEL SPROCKET 4 86 CHECKING THE REAR WHEEL DRIVE HUB 4 86 INSTALLING THE DRIVE CHAIN 4 86 ...

Page 152: ...b Parts to remove Q ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Battery negative lead 1 Disconnect 4 Battery positive lead 1 Disconnect 5 Tool band 1 6 Tool 1 7 Upper tail cover bracket 2 8 Battery cover 1 9 Battery 1 10 Battery seat 1 For installation reverse the removal proce dure ...

Page 153: ...rts to remove Q ty Remarks 1 Front cowling inner panel 2 2 Side cowling 2 3 Front turn signal position light coupler 2 Disconnect 4 Front turn signal position light 2 5 Lower cowling 2 6 Side cowling inner panel 2 For installation reverse the removal proce dure ...

Page 154: ...HASSIS on page 4 1 1 ECU coupler 2 Disconnect 2 ECU 1 3 Radiator fan motor relay coupler 1 Disconnect 4 Radiator fan motor relay 1 5 ECU bracket 1 6 Rectifier regulator coupler 1 Disconnect 7 Stator coil lead coupler 1 Disconnect 8 Rectifier regulator bracket 1 9 Rectifier regulator 1 For installation reverse the removal proce dure ...

Page 155: ... CHASSIS on page 4 1 ECU and rectifier regulator Refer to GENERAL CHASSIS on page 4 1 1 Air chamber cover 2 2 Air chamber 2 3 Air chamber bracket 2 4 Air intake air duct cover 2 5 Rear intake air duct upper 2 6 Rear intake air duct lower 2 7 Front intake air duct 2 For installation reverse the removal proce dure ...

Page 156: ... page 4 1 ECU and Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 Air duct Refer to GENERAL CHASSIS on page 4 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Auxiliary light coupler 2 Disconnect 3 Headlight sub wire harness coupler 2 Disconnect 4 Front cowling assembly 1 For installation reverse the removal proce dure ...

Page 157: ... Air duct Refer to GENERAL CHASSIS on page 4 1 Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 1 Rear view mirror 2 2 Meter bracket 1 3 Headlight coupler 1 Disconnect 4 Meter coupler 1 Disconnect 5 Meter assembly 1 6 Ground lead 1 Disconnect 7 Headlight relay coupler 1 Disconnect 8 Headlight relay 1 9 Turn signal relay coupler 1 Disconnect 10 Turn signal relay 1 11 Headlight sub wire h...

Page 158: ...4 7 Removing the meter and headlight Order Job Parts to remove Q ty Remarks 12 Windshield 1 13 Intake air temperature sensor 1 14 Headlight assembly 1 15 Front cowling 1 For installation reverse the removal proce dure ...

Page 159: ...adlight assembly Order Job Parts to remove Q ty Remarks 1 Auxiliary light socket 2 2 Auxiliary light bulb 2 3 Headlight bulb cover 2 4 Headlight bulb 2 5 Headlight harness 1 6 Headlight grille 2 For installation reverse the removal proce dure ...

Page 160: ...2 Refer to ENGINE REMOVAL on page 5 3 3 Passenger seat lock cable 1 4 Passenger seat lock key cylinder 1 5 Lower tail cover bracket 1 6 Passenger seat lock assembly 1 7 Tail brake light lead coupler 1 Disconnect 8 Rear turn signal light lead coupler 2 Disconnect 9 License plate light lead connector 2 Disconnect 10 License plate turn signal light assembly 1 11 Lower tail cover 1 12 Tail brake light...

Page 161: ...to remove Q ty Remarks 1 License plate turn signal light stay 1 2 License plate turn signal light stay plate 1 3 Cover 1 4 Rear turn signal light 2 5 License plate light 1 6 Rear reflector 1 7 Side reflector bracket 1 8 Side reflector 2 9 Mudguard 1 For installation reverse the removal proce dure ...

Page 162: ...ith a screwdriver Make sure that the screw is flush with the fastener s head EAS14B1031 REMOVING THE QUICK FASTENER PUSH TYPE TIP To remove the quick fastener push its center with a screwdriver then pull the fastener out EAS14B1032 INSTALLING THE QUICK FASTENER PUSH TYPE TIP To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cov...

Page 163: ...IP Align the projection a of the passenger seat lock key cylinder 1 to the grooves b of the lower tail cover and lock stay 2 and install EAS14B1038 REMOVING THE FRONT TURN SIGNAL POSITION LIGHTS 1 Remove Stay 1 Front turn signal position light 2 TIP Remove the stay 1 first and then remove the front turn signal position light 2 from the side cowling EAS14B1039 INSTALLING THE FRONT TURN SIGNAL POSIT...

Page 164: ... Side cowling inner panel 1 TIP When removing the side cowling inner panel downward pull out the side cowling inner panel hole from the projection a of the air chamber cover 2 EAS14B1043 INSTALLING THE SIDE COWLING INNER PANELS 1 Install Side cowling inner panel 1 TIP Install the grommet 2 to the side cowling inner panel and insert them into the projection a of the air chamber cover 3 EAS14B1044 R...

Page 165: ...AKE AIR DUCT COV ERS 1 Install Intake air duct cover 1 TIP Align the intake air duct cover tabs a and the tab b of the front cowling 2 as shown in the illustration and install EAS14B1048 INSTALLING THE AIR INTAKE DUCTS 1 Install Rear air intake duct 1 to front air intake duct 2 TIP Insert the rear air intake duct tabs a into the front air intake duct grooves b EAS14B1013 INSTALLING THE REAR VIEW M...

Page 166: ...ror fitting plate 1 to meter bracket 2 TIP Face the mirror fitting plate concave a up and install it to the meter bracket EAS14B1001 REMOVING THE UPPER TAIL COVER 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Passenger seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Upper tail cover 1 a Remove the bolt on the upper tail cover b Remove the quick fasteners on the upper tail cover c Sli...

Page 167: ...l cover 2 Install Passenger seat Refer to GENERAL CHASSIS on page 4 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS14B1054 INSTALLING THE TAIL BRAKE LIGHT 1 Install Tail brake light 1 TIP Fit the tail brake light tabs a into the holes b of the lower tail cover 2 EAS14B1056 ADJUSTING THE RIDER FOOTRESTS 1 Remove Rider footrest right and left WARNING EWA14B1018 When removing the right rider fo...

Page 168: ...and right rider footrest be sure to set them on the same level e Install the rider footrest bolts TIP Install the end a of the exhaust chamber cover 1 within the range b of the exhaust chamber upper cover 2 as shown in the illustration After adjusting the right rider footrest adjust the rear brake pedal and rear brake light switch Refer to ADJUSTING THE REAR DISC BRAKE on page 3 15 Refer to ADJUST...

Page 169: ...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 Loosen 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 170: ...ONT WHEEL 4 19 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 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 171: ...nt wheel axle Front wheel EAS21920 CHECKING THE 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 17 and CHECKING THE WHEELS on page 3 17 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits R...

Page 172: ...BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP 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 whee...

Page 173: ...EEL The following procedure applies 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 TIP 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 Refer to CHASSIS TIGHTENING TOR...

Page 174: ...RONT WHEEL 4 23 WARNING EWA13490 Make sure the brake cable is routed prop erly TIP Make sure that there is enough space between the brake pads before installing the brake cali pers on to the brake discs ...

Page 175: ...liper Refer to REAR BRAKE on page 4 43 1 Locknut left and right 2 Loosen 2 Adjusting bolt left and right 2 Loosen 3 Rear wheel axle nut 1 4 Washer 1 5 Rear wheel axle 1 6 Adjusting block left 1 7 Adjusting block right 1 8 Rear wheel 1 9 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 176: ...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 177: ...REAR WHEEL 4 26 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 178: ...lts 2 4 Remove Wheel axle nut 1 Wheel axle Rear wheel TIP 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 20 2 Check Tire Rear wheel Damage wear ...

Page 179: ...in a crisscross pattern EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 21 EAS22160 INSTALLING THE REAR WHEEL 1 Lubricat...

Page 180: ...r brake caliper bolts WARNING EWA13500 Make sure the brake hose is routed prop erly Rear wheel axle nut 150 Nm 15 m kgf 110 ft lbf Rear brake caliper bolt front side 27 Nm 2 7 m kgf 19 ft lbf Rear brake caliper bolt rear side 22 Nm 2 2 m kgf 16 ft lbf ...

Page 181: ... ty Remarks The following procedure applies to both of the front brake calipers 1 Reflector 1 2 Reflector bracket 1 3 Brake hose holder 1 4 Front brake caliper 1 5 Brake pad clip 4 6 Brake pad pin 2 7 Brake pad spring 2 8 Brake pad 4 9 Bleed screw 1 For installation reverse the removal proce dure ...

Page 182: ...servoir 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 connector 2 Disconnect 9 Union bolt 1 10 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 proce du...

Page 183: ...4 32 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 installation reverse the removal proce dure ...

Page 184: ...ks The following procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Reflector 1 2 Reflector bracket 1 3 Union bolt 1 4 Washer 2 5 Brake hose 1 6 Brake caliper 1 For installation reverse the removal proce dure ...

Page 185: ...er 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 dust seal 6 7 Brake caliper piston seal 6 8 Bleed screw 1 For installation reverse the removal proce dure ...

Page 186: ...S22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 18 2 Check Brake discs 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 ...

Page 187: ...f If the brake disc deflection cannot be brought within specification replace the brake disc 6 Install Front wheel Refer to FRONT WHEEL on page 4 18 EAS14B1004 REPLACING THE FRONT BRAKE PADS TIP When 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 Br...

Page 188: ...c rotation 6 Install Brake pad pins Brake pad clips Brake caliper 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 13 8 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 EAS22300 REMOVING THE FRONT BRAKE CALI...

Page 189: ...e joint opening b to force out the left side pistons from the brake caliper WARNING EWA14B1002 Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the previous steps to force out the right side pistons from the brake caliper EAS22390 CHECKING THE FRONT BRAKE CALIPERS 1 Check Brake caliper pis...

Page 190: ...on dust seals and brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake calipers 1 Install Brake pads Brake pad springs Brake pad pins 2 Install Brake caliper 1 Copper washers Brake hose 2 Union bolt 3 Brake hose holder WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUT...

Page 191: ...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 13 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylin der drain the brake...

Page 192: ... BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark a facing up First tighten the upper bolt then the lower bolt 2 Install 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 49 TIP While holding the br...

Page 193: ...t enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock 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 16 5 Check Brake fluid level Below the minimum level mark a Add the ...

Page 194: ...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 195: ...IC BRAKE SYSTEM on page 3 16 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 Union bolt 1 8 Washer 2 9 Brake hose 1 10 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 196: ...ake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Adjusting nut 1 3 Brake master cylinder kit 1 4 Hose joint 1 5 O ring 1 6 Brake master cylinder body 1 For installation reverse the removal proce dure ...

Page 197: ...REAR BRAKE 4 46 Removing the rear brake calipers Order Job Parts to remove Q ty Remarks 1 Union bolt 1 2 Washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 198: ...rts 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 dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 For installation reverse the removal proce dure ...

Page 199: ...KING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 24 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 35 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification ...

Page 200: ...stall 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 13 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 ...

Page 201: ...550 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 dust seal and brake caliper piston seal EAS22640 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 S...

Page 202: ...LLING THE REAR BRAKE CALIPER 1 Install Brake caliper 1 temporarily Washers Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 49 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 Bra...

Page 203: ... 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 13 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Union bolt 1 Washers 2 Brake hose 3 TIP To co...

Page 204: ... to CABLE ROUTING on page 2 49 ECA14B1004 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown Face the brake hose paint mark b to the rear master cylinder and install so that the paint mark is facing up 2 Fill Brake fluid reservoir to the maximum level mark c WARNING EWA13090 Use only the designated brake fluid Other brake fluids...

Page 205: ...3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 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 13 5 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 15 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE ...

Page 206: ...efer to GENERAL CHASSIS on page 4 1 Air duct Refer to GENERAL CHASSIS on page 4 1 Front cowling Refer to GENERAL CHASSIS on page 4 1 Front brake master cylinder Refer to FRONT BRAKE on page 4 30 1 Grip end 2 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever assembly 1 7 Throttle cable housing 1 8 Throttle cable 2 ...

Page 207: ...switch 1 11 Handlebar pinch bolt 2 Loosen 12 Handlebar bolt 2 Loosen 13 Upper bracket pinch bolt 2 Loosen 14 Steering stem nut 1 15 Main switch coupler 2 Disconnect 16 Clutch cable guide 1 17 Upper bracket 1 18 Left handlebar 1 19 Right handlebar 1 20 Grip end damper 2 For installation reverse the removal proce dure ...

Page 208: ... HANDLEBARS 1 Check Left handlebar 1 Right handlebar 2 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried EAS22900 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that ...

Page 209: ...the hole b on the left handlebar There should be 2 0 2 5 mm 0 08 0 10 in of clearance between left handlebar switch and clutch lever holder 7 Install Handlebar grip Grip end a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA14B1007 Do not touch the...

Page 210: ...DLEBARS 4 59 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 32 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 211: ...e front fork legs Side cowling Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 18 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 For installation reverse the removal proce dure ...

Page 212: ...remove Q ty Remarks The following procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Nut 1 5 Spacer 1 6 Upper spring seat 1 7 Fork spring 1 8 Lower spring seat 1 9 Outer tube 1 10 Dust seal 1 11 Oil seal clip 1 12 Oil seal 1 13 Washer 1 ...

Page 213: ...e front fork legs Order Job Parts to remove Q ty Remarks 14 Damper rod assembly 1 15 Damper adjusting rod 1 16 Damper adjusting valve 1 17 Damper adjusting valve spring 1 18 Inner tube 1 For installation reverse the removal proce dure ...

Page 214: ...inch bolts 2 Handlebar bolt 3 Cap bolt 4 Lower bracket pinch bolts 5 WARNING EWA14B1009 Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove Front fork leg EAS14B1007 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Position the cap bolt collar 1 as shown in the illustration by turning the spring preload adju...

Page 215: ...cap bolt e Remove the rod holder and fork spring compressor f Remove the nut and spacer 3 Drain Fork oil TIP Stroke the damper rod 1 several times while draining the fork oil 4 Remove Dust seal Oil seal clip 1 with a flat head screwdriver Oil seal Washer 5 Remove Damper rod assembly TIP Remove the damper rod assembly with the damper rod holder 1 EAS23010 CHECKING THE FRONT FORK LEGS The following ...

Page 216: ...ge wear Replace Cap bolt collar projections 2 Cracks damage Replace EAS14B1008 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA14B1010 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts ...

Page 217: ...with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Washer Oil seal 1 with the fork seal driver 2 Recommended oil Suspension oil M1 or equiva lent Damper rod assembly 75 Nm 7 5 m kgf...

Page 218: ... front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly because the fork oil may spurt out Fork seal driver 90890 01442 Adjustable fork seal driver 36 4...

Page 219: ... spring 2 Upper spring seat 3 Spacer 4 Nut 5 Damper adjusting valve spring 6 Damper adjusting valve 7 Damper adjusting rod 8 Washer 9 Cap bolt 10 with O ring a Remove the rod puller attachment b Install the under spring seat c Install the fork spring TIP Install the spring with the smaller pitch a fac ing up A d Install the upper spring seat e Install the spacer f Install the nut g Reinstall the r...

Page 220: ...ections a on the cap bolt collar 3 TIP Hold the nut 1 using a proper tool that has a thickness b of 4 0 mm 0 16 in or less o Remove the rod holder and fork spring compressor 16 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts...

Page 221: ...ch bolt 3 Upper bracket pinch bolt 4 4 Check Cable routing TIP Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 49 5 Install Plastic band 1 TIP Fasten the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRO...

Page 222: ... CHASSIS on page 4 1 Front fork legs Refer to FRONT FORK on page 4 60 Handlebars Refer to HANDLEBARS on page 4 55 1 Horn lead connector 2 Disconnect 2 Horn 1 3 Front brake hose joint 1 4 Front brake hose joint bracket 1 5 Lower bracket cover 1 6 Steering damper coupler 1 Disconnect 7 Steering damper 1 8 Steering damper bracket 1 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 ...

Page 223: ...er ring nut 1 13 Lower bracket 1 14 Upper bearing cover 1 15 Upper bearing inner race 1 16 Upper bearing 1 17 Lower bearing 1 18 Lower bearing inner race 1 19 Lower bearing dust seal 1 20 Upper bearing outer race 1 21 Lower bearing outer race 1 For installation reverse the removal proce dure ...

Page 224: ...aring races a Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new dust seal and new bearing races ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whenever the st...

Page 225: ...ARS on page 4 55 TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 69 TIP Temporarily tighten the upper and lower bracket pinch bolts EAS14B1005 CHECKING THE STEERING DAMPER 1 Check Steering damper body Damage oil leaks Replace It replace with the assembly Steering damper rod Bends scratch Replace It replace with the assembly ...

Page 226: ... Passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Muffler Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm collar 1 2 Connecting arm 1 3 Relay arm collar 1 4 Relay arm 1 5 Collar 3 6 Oil seal 6 7 Bearing 4 8 Rear shock absorber assembly 1 9 Rear shock absorber assembly bracket 1 10 Exhaust chamber stay 1 For installation reverse the removal proce dur...

Page 227: ...se the gas pressure drill a 2 0 3 0 mm 0 08 0 12 in hole through the rear shock absorber at a point 40 mm 1 57 in 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 fal...

Page 228: ...all Bearing 1 Oil seals 2 to the relay arm Relay arm 3 Connecting arm 4 TIP When installing the oil seals to the relay arm or connecting arm face the character stamp of the oil seals outside EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Collars Bearings 2 Install Rear shock absorber assembly TIP Install the rear shock absorber assembly lower bolt from the left Recommended lubric...

Page 229: ... nut 4 Install Connecting arm TIP When installing the connecting arm lift up the swingarm 5 Tighten Connecting arm and swingarm nut Rear shock absorber assembly bracket nut 92 Nm 9 2 m kgf 66 ft lbf Rear shock absorber assembly lower nut 40 Nm 4 0 m kgf 29 ft lbf Connecting arm and swingarm nut 40 Nm 4 0 m kgf 29 ft lbf ...

Page 230: ...4 24 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 75 1 Drive chain guard 1 2 Rear fender 1 3 Left footrest 1 4 Drive chain guide 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 Collar 1 12 Dust cover 1 13 Spacer 1 ...

Page 231: ...SWINGARM 4 80 Removing the swingarm Order Job Parts to remove Q ty Remarks 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Bearing 2 For installation reverse the removal proce dure ...

Page 232: ...m from side to side c If the swingarm side play is out of specifica tion check the spacer bearings collar and dust cover 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 spacer bearings collar and dust cover 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 85 5 Remove Pivot shaft...

Page 233: ... Wash Pivot shaft Dust cover Spacer Washers Bearings 4 Check Dust cover 1 Spacer 2 Collar 3 Bearings 4 Damage wear Replace EAS14B1011 INSTALLING THE SWINGARM 1 Lubricate Bearings Spacer Dust cover Pivot shaft 2 Install Bearings 1 Bearing 2 Circlip 3 Oil seal 4 Damper rod holder 22 mm 90890 01365 Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease Installed depth o...

Page 234: ...in slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 5 Dust cover 6 Collar 7 Swingarm 8 Pivot shaft A Left side B Right side Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut 65 Nm 6 5 m kgf 47 ft lbf Ring nut wrench 90890 01507 YM 01507 Pivot shaft nut 105 Nm 10 5 m kgf 75 ft lbf Drive chain slack when adjust ing the drive chain 25 0 35 0 mm ...

Page 235: ...Remarks Drive chain Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Shift pedal 1 5 Drive sprocket cover 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive chain guide drive sprocket side 1 9 Drive sprocket 1 10 Drive chain 1 For installation reverse the removal proce dure ...

Page 236: ...procket as a set TIP While measuring the 15 link section push down on 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 ...

Page 237: ...teeth Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 28 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 28 EAS23490 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA14B1023 Be sure to put on safety goggles when working a When press fitting the c...

Page 238: ... a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 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 th...

Page 239: ...ING THE CYLINDER HEAD 5 26 INSTALLING THE CYLINDER HEAD 5 26 VALVES AND VALVE SPRINGS 5 28 REMOVING THE VALVES 5 30 CHECKING THE VALVES AND VALVE GUIDES 5 31 CHECKING THE VALVE SEATS 5 32 CHECKING THE VALVE SPRINGS 5 34 CHECKING THE VALVE LIFTERS 5 35 INSTALLING THE VALVES 5 35 GENERATOR 5 37 REMOVING THE GENERATOR 5 38 INSTALLING THE GENERATOR 5 38 STARTER CLUTCH 5 40 REMOVING THE STARTER CLUTCH ...

Page 240: ...RY DRIVEN GEAR 5 66 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 66 INSTALLING THE CLUTCH 5 66 SHIFT SHAFT 5 69 CHECKING THE SHIFT SHAFT 5 70 CHECKING THE STOPPER LEVER 5 70 INSTALLING THE SHIFT SHAFT 5 70 CRANKCASE 5 71 DISASSEMBLING THE CRANKCASE 5 73 CHECKING THE CRANKCASE 5 73 ASSEMBLING THE CRANKCASE 5 73 CONNECTING RODS AND PISTONS 5 75 REMOVING THE CONNECTING RODS AND PISTONS 5 76 CHECKING ...

Page 241: ... 5 90 REMOVING THE TRANSMISSION 5 95 CHECKING THE SHIFT FORKS 5 95 CHECKING THE SHIFT DRUM ASSEMBLY 5 96 CHECKING THE TRANSMISSION 5 96 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 97 INSTALLING THE TRANSMISSION 5 97 ...

Page 242: ...1 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 EWA14B1017 To prevent sparking ground all speak plug leads before cranking the engine TIP The difference in compression pressure between cylinders should not exceed 100 kPa 1 kgf cm 14 ...

Page 243: ...tallation reverse the removal proce dure Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Replace Same as without oil Piston valves or cyl inder head gasket possibly defective Replace Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 244: ...on page 4 1 Side cowling Refer to GENERAL CHASSIS on page 4 1 Rear brake master cylinder Refer to REAR BRAKE on page 4 43 Radiator lower bracket Refer to RADIATOR on page 6 1 1 Left muffler cover 1 2 Left muffler pipe cover 1 3 Left muffler pipe protector clamp 1 Loosen 4 Left muffler pipe protector 1 5 Right muffler cover 1 6 Right muffler pipe cover 1 7 Right muffler pipe protector clamp 1 Loose...

Page 245: ...ght muffler clamp 1 Loosen 13 Right muffler 1 14 Right muffler gasket 1 15 Rear brake light switch coupler 1 Disconnect 16 Right footrest assembly 1 17 Exhaust chamber cover 1 18 Rear brake light switch 1 19 O2 sensor lead coupler 1 Disconnect 20 O2 sensor 1 21 Exhaust chamber clamp 1 22 Exhaust chamber 1 23 Exhaust chamber gasket 1 24 Collar 1 ...

Page 246: ...b Parts to remove Q ty Remarks 25 Exhaust chamber protector 1 26 Exhaust chamber pipe protector clamp 1 Loosen 27 Exhaust chamber pipe protector 1 28 Exhaust chamber bracket 1 29 Exhaust pipe 1 30 Exhaust pipe gasket 4 For installation reverse the removal proce dure ...

Page 247: ...ing Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 Radiator Refer to RADIATOR on page 6 1 Shift pedal Refer to CHAIN DRIVE on page 4 84 Drive sprocket Refer to CHAIN DRIVE on page 4 84 Throttle body assembly Refer to THROTTLE BODIES on page 7 11 1 Sub wire harness coupler 1 Disconnect 2 Crank...

Page 248: ...rts to remove Q ty Remarks 5 Speed sensor lead coupler 1 Disconnect 6 Oil level switch lead coupler 1 Disconnect 7 Gear position sensor coupler 2 Disconnect 8 Engine ground lead 2 Disconnect 9 Clutch cable 1 Disconnect For installation reverse the removal proce dure ...

Page 249: ...el bracket 1 5 Sidestand assembly 1 6 Sidestand switch 1 7 Sidestand switch bracket 1 8 Engine mounting bolt front right side 1 9 Engine mount collar front right side 2 10 Engine mount collar front right side 1 11 Engine mounting bolt front left side 1 12 Left engine mount collar 1 13 Left engine mount damper 1 14 Engine mount nut rear upper side 1 15 Engine mount nut rear lower side 1 ...

Page 250: ...ving the engine Order Job Parts to remove Q ty Remarks 16 Engine mount bolt rear upper side 1 17 Engine mount bolt rear lower side 1 18 Engine 1 19 Engine mount adjusting bolt 2 For installation reverse the removal proce dure ...

Page 251: ...together with damper 2 Engine mounting bolt front left side 3 temporary tighten TIP When installing the engine mount collar front left side set the damper toward the engine 5 Install Engine mount collars front right side 1 Engine mount collar front right side 2 Engine mounting bolt front right side 3 temporary tighten 6 Tighten Engine mount adjusting bolts TIP Use the pivot shaft wrench 1 and pivo...

Page 252: ...ht footrest assembly Refer to ADJUSTING THE RIDER FOOTRESTS on page 4 16 2 Install Muffler gasket 1 to muffler Muffler TIP When installing the muffler gasket set the surface a with the carbon to the back When installing the catalyst pipe assembly and muffler clamp tip of the tab b should not contact the edge of the muffler gasket Engine mounting nut rear lower side 51 Nm 5 1 m kgf 37 ft lbf Engine...

Page 253: ...ENGINE REMOVAL 5 12 Installed depth of gasket c 3 5 mm 0 14 in ...

Page 254: ...fer to RADIATOR on page 6 1 Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 21 Throttle body Refer to THROTTLE BODIES on page 7 11 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 21 1 Ignition coil coupler 4 Disconnect 2 Ignition coil 4 3 Spark plug 4 4 Cylinder identification sensor coupler 1 Disconnect 5 Cylinder identification sensor 1 6 O ring 1 7 Cylinder head cover 1...

Page 255: ...CAMSHAFTS 5 14 For installation reverse the removal proce dure Removing the cylinder head cover Order Job Parts to remove Q ty Remarks ...

Page 256: ...r to GENERATOR on page 5 37 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 3 4 Dowel pin 6 5 Exhaust camshaft cap 3 6 Dowel pin 6 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Intake camshaft sprocket 1 10 Exhaust camshaft sprocket 1 11 Dowel pin 2 12 Intake side timing chain guide 1 13 Exhaust side timing chain guide 1 ...

Page 257: ...the camshafts Order Job Parts to remove Q ty Remarks 14 Pickup rotor 1 Refer to PICKUP ROTOR on page 5 43 15 Timing chain 1 16 Crankshaft sprocket 1 17 Collar 1 18 Woodruff key 1 For installation reverse the removal proce dure ...

Page 258: ...rk a on the pickup rotor with the crankcase mat ing surface b TIP You can check that the 1 piston is at BTDC 105 by checking to see that the intake cam shaft sprocket air intake timing mark c and exhaust camshaft sprocket air exhaust timing mark d are aligned with the cylinder head surface e 3 Remove Timing chain tensioner 1 Gasket 4 Remove Camshaft caps 1 Dowel pins ECA13720 To prevent damage to ...

Page 259: ...ing scratches Replace the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft 3 Measure Camshaft runout Out of specification Replace Camshaft wrench 90890 04143 YM 04143 Camshaft lobe dimension limit Intake A 37 350 37 450 mm 1 4705 1 4744 in Limit 37 250 mm 1 4665 in Intake B 28 034 28 134 mm 1 1037 1 1076 in Limit 27 934 mm 1 0998 in Exhaust A 36 450 36...

Page 260: ...tigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 5 Measure Camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylin der head and the camshaft caps as a set EAS23870 CHECKING THE TIMING CHAIN AND SPROCKET 1 Check Timing chain Damage stiffness Replace the timing chain camshaft sprockets and crankshaft sprocket as...

Page 261: ...pressing the timing chain tensioner rod mount clip 3 into groove 4 and lock the timing chain tensioner rod c Push the timing chain tensioner rod in direction c d Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction d If not smooth replace the timing chain ten sioner assembly EAS24000 INSTALLING THE CAMSHAFTS 1 Install Woodruff key...

Page 262: ... at BTDC 105 align the K mark a with the crankcase mating surface b 5 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 ECA14B1012 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket...

Page 263: ...k ER Exhaust right side camshaft cap mark Make sure the arrow mark a on each cam shaft points towards the right side of the engine When installing the camshaft cap face the hole with the screw thread b on the cam shaft cap to the left side of the engine 8 Install Camshaft cap bolts ECA14B1011 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or da...

Page 264: ...iming mark c Make sure the punch mark c on the camshaft sprocket is aligned with the cyl inder head mating surface d Out of alignment Adjust Refer to the installation steps above 12 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 5 13 Install Pickup coil rotor cover 2 Refer to PICKUP ROTOR on page 5 43 14 Install Cylinder head cover gasket Cylin...

Page 265: ...CAMSHAFTS 5 24 Tighten the cylinder head cover bolts stages and in a crisscross pattern Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 266: ...ove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 3 Intake camshaft Refer to CAMSHAFTS on page 5 13 Exhaust camshaft Refer to CAMSHAFTS on page 5 13 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure ...

Page 267: ...itanium valves with the cylinder head Refer to CHECKING THE VALVE SEATS on page 5 32 Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder 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 4...

Page 268: ...th engine oil 4 Tighten Cylinder head nuts 1 10 Cylinder head bolts 11 12 TIP Tighten the cylinder head nuts in the tightening sequence as shown and torque them in 3 stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAM SHAFTS on page 5 20 Cylinder head nut 1st 10 Nm 1 0 m kgf 7 2 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf 3rd Bolt 1 7 10 115 125 Bolt 8 9 130 140 Cylinder head bo...

Page 269: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 25 1 Intake valve lifter 8 2 Intake valve pad 8 3 Intake valve cotter 16 4 Intake valve upper spring seat 8 5 Intake valve spring 8 6 Intake valve 8 7 Intake valve stem seal 8 8 Intake valve lower spring seat 8 9 Intake valve guide 8 ...

Page 270: ...Q ty Remarks 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 8 16 Exhaust valve stem seal 8 17 Exhaust valve lower spring seat 8 18 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 271: ... valve seat width Refer to CHECKING THE VALVE SEATS on page 5 32 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 4 Remove Upper spring ...

Page 272: ...uide remover 1 b Install the new valve guide with the valve guide 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 TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve s...

Page 273: ...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 cylin der 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 274: ...acing the intake valves replace the intake valves without lapping the valve seats and valve faces When replacing the cylinder head or intake valve guides use new valves to lap the valve seats and then replace them with new intake valves a Apply a coarse lapping compound a to the valve face ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply mol...

Page 275: ...nd lap the valve 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 Valve spring free length Free length intake 39 33 mm 1 55 in Limit 37 36 mm 1 47 in Free length exhaust 37 96 m...

Page 276: ...2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its origi nal place Refer to the following embossed marks Intake valve Blue paint mark Exhaust valve 14B Install the valve springs with the larger pitch a facing up When i...

Page 277: ...itting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP 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 b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach...

Page 278: ...r case Refer to AIR FILTER CASE on page 7 5 Side cowling Refer to GENERAL CHASSIS on page 4 1 Stator coil lead coupler Refer to GENERAL CHASSIS on page 4 1 1 Generator cover 1 2 Generator cover gasket 1 3 Dowel pin 2 4 Washer 1 5 Generator rotor 1 6 Stator coil lead holder 1 7 Stator coil assembly 1 For installation reverse the removal proce dure ...

Page 279: ...r Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 3 Tighten Generator rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A Rotor puller 2K7 85555 00...

Page 280: ...GENERATOR 5 39 4 Apply Sealant onto the stator coil lead grommet 1 Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 281: ... starter clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 59 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch holder 1 4 Starter clutch 1 5 Starter idle gear 1 For installation reverse the removal proce dure ...

Page 282: ...h gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the clutch housing assembly 2 and hold the clutch housing assembly b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terclockwise B it should turn freel...

Page 283: ...STARTER CLUTCH 5 42 Fix the flat surface of the clutch housing assembly with the sheave holder Sheave holder 90890 01701 Primary clutch holder YS 01880 A ...

Page 284: ...er Refer to GENERATOR on page 5 37 Air filter case Refer to AIR FILTER CASE on page 7 5 1 Timing check bolt 1 2 Pickup rotor cover 1 1 3 O ring 1 4 Dowel pin 2 5 Crankshaft position sensor coupler 1 Disconnect 6 Pickup rotor cover 2 1 7 Pickup rotor cover 2 gasket 1 8 Crankshaft position sensor 1 9 Pickup rotor 1 For installation reverse the removal proce dure ...

Page 285: ... the pickup rotor align the woodruff key a with the groove b on the pickup rotor Face the K mark on the pickup rotor outer side of the vehicle and install 2 Tighten Pickup rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet 1 Sheave holder 90890 01701 Primary clutch holder YS 01...

Page 286: ...PICKUP ROTOR 5 45 Yamaha bond No 1215 Three Bond No 1215 90890 85505 ...

Page 287: ...d Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 11 Engine outlet pipe Refer to THERMOSTAT on page 6 8 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 288: ...r 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 O ring 1 10 Rear cover 1 For installation reverse the removal proce dure ...

Page 289: ... resistances commu tator 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 brush holder 6 Measure Brush spring force Out of specification Replace the brush holder Limit 23 5 mm 0 93 in Mica un...

Page 290: ...er 4 and push the brush 5 inside until it touches the armature assem bly 2 Install Rear cover 1 TIP Align the tab a on the brush holder 2 with the tab b in the rear cover 3 Install Washer Nut 1 4 Install Starter motor yoke 1 Gaskets 2 Front cover 3 Starter motor assembling bolts 4 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers Brush spring...

Page 291: ...ELECTRIC STARTER 5 50 ...

Page 292: ...GING THE ENGINE OIL on page 3 27 Fuel tank Refer to FUEL TANK on page 7 1 Coolant reservoir Refer to RADIATOR on page 6 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 Clutch assembly Refer to CLUTCH on page 5 59 Water pump inlet pipe Refer to RADIATOR on page 6 1 Water pump outlet pipe Refer to OIL COOLER on page 6 5 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch 1 3 Oil level...

Page 293: ...1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 1 11 Relief valve assembly 1 12 Oil water 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 ...

Page 294: ...p Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Circlip 1 3 Oil pump housing 1 4 Bearing 1 5 Dowel pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For installation reverse the removal proce dure ...

Page 295: ...p assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Cracks damage wear Replace Oil pump housing 2 Cracks damage wear Replace the oil water pump assembly 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clear ance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil water p...

Page 296: ...E OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 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 EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommende...

Page 297: ...BLY 1 Install O ring onto the lower crankcase 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 TIP Install the oil water pump assembly drive chain 1 onto the oil water pump assembly drive sprocket 2 ECA14B1018 After installing the oil water pump assem bly drive chain and drive sprocket make sure the o...

Page 298: ... Oil pan gasket Oil pan Oil level switch lead holder Oil level switch O ring Engine oil drain bolt Gasket Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil delivery pipe 1 bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Relief valve assembly bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil strainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil pipe bolt 10 Nm 1 0 m kgf 7 2 ft ...

Page 299: ...OIL PUMP 5 58 TIP Tighten the oil pan bolts in stages and in a crisscross pattern Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf ...

Page 300: ...e clutch cover Order Job Parts to remove Q ty Remarks Engine oil Drain 1 Pull lever cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 3 6 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 301: ...e pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal proce dure ...

Page 302: ...ssion spring 6 2 Pressure plate 1 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 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 1 1 11 Clutch boss nut 1 12 Spring 3 13 Clutch boss 1 14 Pressure plate 2 1 15 Conical spring washer 1 ...

Page 303: ...CLUTCH 5 62 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Clutch housing assembly 1 18 Bearing 1 19 Washer 1 For installation reverse the removal proce dure ...

Page 304: ...ve Compression spring bolts 1 Compression springs Pressure plate 1 2 Pull rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate 3 5 Straighten the clutch boss nut rib a 6 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 7 Remove Clutch boss nut Springs Clutch boss Universal...

Page 305: ...eplace 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 TIP Perform the thickness measurement without applying the oil This step should be performed only if the fric tion plates and clutch plates ...

Page 306: ...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 TIP 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 Replace the ...

Page 307: ...rankshaft as a set Excessive noise during operation Replace the clutch housing and crank shaft as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft as a set 2 Check Pull rod bearing Damage wear Replace EAS25240 INSTALLING THE CLUTCH 1 Install Washer Bearing Clutch housing ass...

Page 308: ...utch boss nut at a cutout a in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align a projection on the friction plate with the punch...

Page 309: ...clutch cover bolts b shown in the illustration Tighten the clutch cover bolts in stages and in a crisscross pattern 9 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP Make sure that the mark a on the pull lever is facing down The end of the pull lever should be closest to the clutch cover match mark b when there is no free play of the pull lever Make sure that the pull rod teeth and pul...

Page 310: ...CHAIN DRIVE on page 4 84 Clutch assembly Refer to CLUTCH on page 5 59 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Bearing 1 13 Oil seal 1 14 Bearing 1 For installation reverse the removal proce dure ...

Page 311: ...EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum se...

Page 312: ...on page 5 46 Stator coil assembly Refer to GENERATOR on page 5 37 Pickup rotor Refer to PICKUP ROTOR on page 5 43 Clutch housing assembly Refer to CLUTCH on page 5 59 Shift shaft assembly Refer to SHIFT SHAFT on page 5 69 Oil water pump assembly Refer to OIL PUMP on page 5 51 1 Clutch cable holder 1 2 Main gallery plug 1 2 3 Main gallery plug 2 1 4 Union bolt 1 5 Crankcase breather hose 1 6 Speed ...

Page 313: ...remove Q ty Remarks 8 Crankcase breather cover 1 9 Crankcase breather cover gasket 1 10 Crankcase breather case 1 11 Crankcase breather case gasket 1 12 Lower crankcase 1 13 Dowel pin 3 14 Crankcase baffle plate 4 For installation reverse the removal proce dure ...

Page 314: ...he crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25650 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft journal bearings with the recommended lubricant 2 Apply Sealant onto the crankcase mating surfaces TIP Do not allow any sealant t...

Page 315: ...houlder bolts 21 22 M6 60 mm bolts 30 32 36 M6 50 mm bolts 23 25 27 29 40 M6 40 mm bolts 26 37 39 7 Tighten Crankcase bolts 1 10 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque TIP Tighten the bolts in the tightening sequence cast on the crankcase 8 Tighten Crankcase bolts 11 40 TIP Tighten the bolts in the tightening sequence cast on the cran...

Page 316: ... Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 71 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 13 Dowel pin 2 For installation reverse the removal proce dure ...

Page 317: ...o drive the piston pin out TIP 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 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the...

Page 318: ...eplace 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 TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit ...

Page 319: ...e Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the pis ton 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 10 mm 0 4 in Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit ...

Page 320: ...cting rod and the big end lower bear ing into the connecting rod cap TIP 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 TIP Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolt thre...

Page 321: ...aft web and the numbers 1 on the con necting rods are used to determine the replacement big end bearings sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 respectively then the bearing size for P1 is EAS26190 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the ...

Page 322: ...utout in the piston 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 the recommended lubricant 6 Check Cylinder stud bolts 7 Install Piston assemblies 1 into the cyl...

Page 323: ... in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the Y marks c on the connect ing rods face towards the left side of the crankshaft Make sure the characters d on both the connecting rod and connecting rod cap are aligned Apply Molybdenum disulfide oil to the bear ing surface of the connecting rod bolt and connecting rod cap 9...

Page 324: ...ied angle do not loosen the bolt and then retighten it Instead replace the connecting rod bolt with a new one and perform the procedure again ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle d After the installation check that the section shown a is flush with each other by touch ing the surface Connecting rod bolt final Specified angle 145 155 ...

Page 325: ...age 5 71 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 76 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft 1 5 Crankshaft journal lower bearing 5 6 Crankshaft journal upper bearing 5 7 Oil nozzle 4 For installation reverse the removal proce dure ...

Page 326: ...urfaces Bearing surfaces Scratches wear Replace the crank shaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings ECA13920 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 ...

Page 327: ...nkshaft journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crank shaft web and the numbers B stamped into the lower crankcase are used to d...

Page 328: ...al bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing por tions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the ...

Page 329: ...r shaft journal bearings 4 Select Balancer shaft journal bearings J1 J4 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bear ing sizes J1 J4 refer to the bearings shown in the bal ancer shaft illustration If J1 J4 are the same use the same size for all of the bearings For example i...

Page 330: ...NCER ASSEMBLY 1 Install Balancer journal upper bearings into the upper crankcase Balancer journal lower bearings into the lower crankcase TIP Align the projections a on the balancer jour nal bearings 1 with the notches b in the crankcases Be sure to install each balancer journal bear ing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the bala...

Page 331: ...Q ty Remarks Lower crankcase Separate Refer to CRANKCASE on page 5 71 1 Drive axle assembly 1 2 Oil seal 1 3 Circlip 1 4 Bearing 1 5 Circlip 1 6 Shift drum 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 assembly 1 14 Oil delivery pipe 2 1 ...

Page 332: ...ISSION 5 91 Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 15 O ring 3 16 Oil baffle plate 1 17 Bearing 2 For installation reverse the removal proce dure ...

Page 333: ...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 4th 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 installation reverse the removal proce dure ...

Page 334: ...s to remove Q ty Remarks 1 Washer 1 2 1st wheel gear 1 3 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 ...

Page 335: ...he drive axle assembly Order Job Parts to remove Q ty Remarks 16 Circlip 1 17 Washer 1 18 2nd wheel gear 1 19 Collar 1 20 Collar 1 21 Oil seal 1 22 Circlip 1 23 Bearing 1 24 Drive axle 1 For installation reverse the removal proce dure ...

Page 336: ...lts 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 delivery pipe 2 1 Bearings 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 guid...

Page 337: ...E 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 Transmission gear dogs Cracks damage rounded edges Replace the defective ...

Page 338: ... lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer EAS26350 INSTALLING THE TRANSMISSION 1 Install Bearing 1 Oil delivery ...

Page 339: ... 4 Install Shift fork R 1 Shift fork L 2 Shift fork guide bar Springs Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the drive axle bearing circlip 4 is ...

Page 340: ...TRANSMISSION 5 99 ...

Page 341: ... 6 5 CHECKING THE OIL COOLER 6 7 INSTALLING THE OIL COOLER 6 7 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 10 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 11 WATER PUMP 6 12 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 ...

Page 342: ... Side cowling Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 1 Radiator cap 1 2 Coolant reservoir hose 1 Disconnect 3 Radiator fan motor coupler 2 Disconnect 4 Radiator outlet hose 1 5 Water pump bypass hose 1 Disconnect 6 Water pump inlet pipe 1 7 Drain bolt 1 8 Copper washer 1 9 O ring 1 10 Oil cooler outlet hose 1 Disconnect 11 Radiator 1 ...

Page 343: ... Job Parts to remove Q ty Remarks 12 Radiator bracket 1 13 Radiator fan 2 14 Thermostat bypass hose 2 1 Disconnect 15 Thermostat bypass hose 3 1 16 Radiator inlet pipe 1 17 Radiator inlet hose 1 For installation reverse the removal proce dure ...

Page 344: ...Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 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 30 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Radia...

Page 345: ... 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 346: ...ling Refer to GENERAL CHASSIS on page 4 1 Lower cowling Refer to GENERAL CHASSIS on page 4 1 ECU Refer to GENERAL CHASSIS on page 4 1 Rectifier regulator Refer to GENERAL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Oil cooler outlet hose 1 2 Oil cooler union bolt 1 3 Gasket 1 4 Oil cooler 1 5 O ring 1 6 Oil cooler inlet hose 1 7 Wat...

Page 347: ...OOLER 6 6 Removing the oil cooler Order Job Parts to remove Q ty Remarks 8 Water jacket joint 1 9 O ring 1 10 Water pump outlet pipe 1 11 O ring 1 12 O ring 1 For installation reverse the removal proce dure ...

Page 348: ...on bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly Make sure the projection a on the oil cooler touches the projection b on the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 30 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL ...

Page 349: ...age 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle body Refer to THROTTLE BODIES on page 7 11 1 Coolant reservoir cover 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir cap 1 5 Coolant reservoir tank 1 6 Thermostat outlet hose 1 7 Thermostat housing cover 1 8 O ring 1 9 Thermostat 1 10 Thermostat housing 1 11 Thermostat inlet hose 1 ...

Page 350: ...hermostat Order Job Parts to remove Q ty Remarks 12 Thermostat bypass hose 2 1 13 Water pump bypass hose 1 14 Joint 1 15 Thermostat bypass hose 1 1 16 Engine outlet pipe 1 17 O ring 1 For installation reverse the removal proce dure ...

Page 351: ...ermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat housing cover 1 Thermostat housing 2 Cracks damage Replace 3 Check Thermostat hoses Thermostat bypass hoses Water pump bypass hose Engine outlet pipe Cracks damage Replace EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat ...

Page 352: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 30 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 353: ...es Q ty Remarks Oil water pump assembly Refer to OIL PUMP on page 5 51 Oil pump rotor Refer to OIL PUMP on page 5 51 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 O ring 1 For installation reverse the removal proce dure ...

Page 354: ...ith a thin flat head screwdriver TIP Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the oil water pump assembly EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 TIP Before installing the oil seal apply tap water or coolant...

Page 355: ...ter surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 2 Water pump housing 3 Mechanical seal installer 4 Middle driven shaft bea...

Page 356: ...WATER PUMP 6 15 ...

Page 357: ...KING THE INTAKE FUNNEL 7 9 INSTALLING THE INTAKE FUNNEL AND LOWER AIR FILTER CASE 7 9 CHECKING THE INTAKE FUNNEL OPERATION 7 9 INSTALLING THE SECONDARY INJECTORS 7 9 INSTALLING THE UPPER AIR FILTER CASE 7 10 INSTALLING THE FUEL HOSE PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE 7 10 THROTTLE BODIES 7 11 CHECKING THE PRIMARY INJECTORS BEFORE REMOVING 7 15 REMOVING THE PRIMARY INJECT...

Page 358: ...pt for California Disconnect 4 Fuel tank breather hose hose joint to rollover valve 1 For California only 5 Fuel tank overflow hose 1 Disconnect 6 Fuel pump coupler 1 Disconnect 7 Fuel sender coupler 1 Disconnect 8 Fuel hose connector cover 1 9 Fuel hose fuel tank side 1 Disconnect 10 Fuel tank breather hose fuel tank to hose joint 1 11 Fuel tank overflow hose fuel tank to hose joint 1 12 Fuel tan...

Page 359: ...FUEL TANK 7 2 Removing the fuel tank and fuel pump Order Job Parts to remove Q ty Remarks 15 Fuel pump 1 16 Fuel pump gasket 1 For installation reverse the removal proce dure ...

Page 360: ...ly disconnect the hose with tools TIP To remove the fuel hose from the fuel pump press the two buttons 1 on the sides of the connector and then remove the hose Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fue...

Page 361: ...stalling the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard Fuel hose connector cover TIP Attach the fuel hose connector cover 1 to the fuel hose connector 2 from the bottom...

Page 362: ...coupler 1 Disconnect 3 Fuel hose secondary injector fuel rail side 1 Disconnect 4 Upper air filter case 1 5 Sub wire harness 1 6 Secondary injector holder 1 7 Secondary injector 4 8 Fuel rail 2 9 Secondary injector joint 1 10 Air filter element 1 11 Intake funnel joint bolt 6 Loosen 12 Intake funnel servo motor coupler 1 Disconnect 13 Air induction system hose air filter case to air cut off valve ...

Page 363: ...he air filter case and secondary injectors Order Job Parts to remove Q ty Remarks 15 Intake funnel servo motor rod assembly 1 16 Intake funnel assembly 1 17 Intake funnel servo motor 1 For installation reverse the removal proce dure ...

Page 364: ...arrow shown press the two but tons 2 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed EAS14B4004 REMOVING THE SECONDARY INJECTORS WARNING EWA14B4001 Check the injectors in a well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the i...

Page 365: ...THE INTAKE FUNNEL ASSEM BLY 1 Remove Intake funnel servo motor rod assembly Intake funnel assembly a Clamp the two tabs a in the direction shown in the illustration and separate the intake funnel assembly from lower air filter case ECA14B4004 Do not remove the bolts 1 from the intake funnel joint EAS14B1081 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Obstruction Replace and check the fuel p...

Page 366: ... to FUEL INJECTION SYSTEM on page 8 33 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 EAS14B4006 INSTALLING THE SECONDARY INJEC TORS ECA14B4001 Always use new O rings When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails or O rings Be careful not to ...

Page 367: ... SIDE AND SECONDARY INJECTOR JOINT SIDE 1 Connect Fuel hose primary injector joint side and secondary injector joint side ECA14B1033 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the sec ondary inje...

Page 368: ...efer to AIR FILTER CASE on page 7 5 1 Canister purge hose throttle body 2 to 3 way joint 1 2 Canister purge hose throttle body 1 to 3 way joint 1 3 3 way joint 1 4 Canister purge hose 3 way joint to canister 1 5 Rollover valve 1 6 Fuel tank breather hose rollover valve to canis ter 1 7 Canister 1 8 Canister bracket 1 For installation reverse the removal proce dure ...

Page 369: ...on sensor coupler 1 Disconnect 3 Sub wire harness coupler 2 Disconnect 4 Intake air pressure sensor coupler 1 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Coolant temperature sensor coupler 1 Disconnect 7 Fuel hose 2 8 Throttle cable accelerator cable 1 Disconnect 9 Throttle cable decelerator cable 1 Disconnect 10 Throttle body joint clamp 4 Loosen 11 Throttle body assembly 1 12 Thrott...

Page 370: ...3 Removing the throttle body assembly Order Job Parts to remove Q ty Remarks 14 Crankshaft position sensor coupler 1 Disconnect 15 Heat protector 1 16 Throttle body joint 2 For installation reverse the removal proce dure ...

Page 371: ...nect 3 Primary injector coupler 3 1 Disconnect 4 Primary injector coupler 4 1 Disconnect 5 Sub wire harness 1 6 Intake air pressure sensor hose 5 7 Intake air pressure sensor 1 8 Fuel rail 2 9 Primary injector joint 1 10 Primary injector 4 11 Throttle position sensor 1 12 Accelerator position sensor 1 13 Throttle bodies 1 For installation reverse the removal proce dure ...

Page 372: ...om the battery terminal before checking the injectors 1 Remove Fuel tank Fuel connector Air filter case Throttle bodies 2 Remove Sub wire harness Primary injectors a Remove the fuel rail screws 1 as shown 3 Remove Fuel rails 1 Primary injector joint 2 EAS14B4009 CHECKING THE PRIMARY INJECTORS 1 Check Injectors Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Re...

Page 373: ...y Do not open the throttle valves quickly Do not subject the throttle bodies to excessive force Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor clean ing solution Do not apply cleaning solvent directly to any plastic parts sensors or seals Do not directly push the throttle valves to open them Do not touch the bypass air screw a with a white paint mark otherw...

Page 374: ...es using compressed air g Make sure that there are no carbon depos its or other foreign materials in any of the passages a in each throttle body or in the space b between the throttle valve shaft and the throttle body 3 Adjust Throttle bodies synchronizing Out of specification Replace the throt tle bodies Refer to SYNCHRONIZING THE THROTTLE BODIES on page 3 9 EAS14B4010 INSTALLING THE PRIMARY INJE...

Page 375: ...ir pressure or damage could occur f Close the valve on the injector pressure adapter g Check that the specified air pressure is held for about one seconds Pressure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Replace the fuel injectors EAS14B1071 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the fuel tank bolt and holdup the fuel tank b Dis...

Page 376: ...Simultaneously press and hold the SELECT and RESET buttons turn the main switch to ON and continue to press the buttons for 8 seconds more TIP dIAG appears on the odometer LCD f Diagnostic code number D 01 is selected g Adjust the position of the throttle position sensor angle so that 12 21 can appear in the meter h After adjusting the throttle position sensor angle tighten the throttle position s...

Page 377: ...ously press and hold the SELECT and RESET buttons turn the main switch to ON and continue to press the buttons for 8 seconds more TIP dIAG appears on the odometer LCD f Diagnostic code number D 14 is selected g Adjust the position of the accelerator posi tion sensor angle so that 12 22 can appear in the meter h After adjusting the accelerator position sen sor angle tighten the accelerator position...

Page 378: ...AIR INDUCTION SYSTEM 7 21 EAS27040 AIR INDUCTION SYSTEM ...

Page 379: ...AIR INDUCTION SYSTEM 7 22 1 Lower air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 380: ...r case duct 2 2 Atmospheric pressure sensor coupler 1 Disconnect 3 Air filter case duct 1 4 Atmospheric pressure sensor hose 1 Disconnect 5 Atmospheric pressure sensor 1 6 Air induction system solenoid coupler 1 Disconnect 7 Air induction system hose air filter case to air cut off valve 1 8 Air induction system hose air cut off valve to reed valve cover 2 9 Air cut off valve 1 For installation rev...

Page 381: ...IR INDUCTION SYSTEM 7 24 Removing the reed valves Order Job Parts to remove Q ty Remarks 1 Reed valve cover 2 2 Reed valve assembly 2 3 Reed valve plate 4 For installation reverse the removal proce dure ...

Page 382: ...the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the 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 v...

Page 383: ... INDUCTION SYSTEM 1 Install Reed valves Reed valve stoppers Reed valve base 2 Install Reed valve plate TIP Align the projection a on the cylinder head cover 1 with the hole b in the reed valve plate Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 3 Install Reed valve cover A Exhaust side Reed valve cover bolt 10 Nm 1 0 m kgf 7 2...

Page 384: ...AIR INDUCTION SYSTEM 7 27 ...

Page 385: ... 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 37 DIAGNOSTIC MODE 8 38 TROUBLESHOOTING DETAILS 8 44 FUEL PUMP SYSTEM 8 97 CIRCUIT DIAGRAM 8 97 TROUBLESHOOTING 8 99 ELECTRICAL COMPONENTS 8 101 CHECKING THE SWITCHES 8 105 CHECKING THE BULBS AND BULB SOC...

Page 386: ...MOTOR 8 121 CHECKING THE COOLANT TEMPERATURE SENSOR 8 122 CHECKING THE THROTTLE POSITION SENSOR 8 122 CHECKING THE ACCELERATOR POSITION SENSOR 8 123 CHECKING THE THROTTLE SERVO MOTOR 8 123 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 124 CHECKING THE ATMOSPHERIC PRESSURE SENSOR 8 124 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8 125 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 125 CHECKING THE INTAKE...

Page 387: ......

Page 388: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 389: ... engine control unit 21 Ignition coil 1 22 Ignition coil 2 23 Ignition coil 3 24 Ignition coil 4 25 Spark plug 40 Crankshaft position sensor 44 Cylinder identification sensor 45 Lean angle sensor 62 Right handlebar switch 65 Engine stop switch 67 Gear position sensor 94 Ignition fuse 95 Engine ground 96 Battery negative lead ...

Page 390: ...w to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the side stand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed an...

Page 391: ...tery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Gear position sensor 12 Battery negative lead 13 Engine ground ...

Page 392: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 109 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 116 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI T...

Page 393: ...lebar switch 10 Check the gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR on page 8 127 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 115 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE ...

Page 394: ...ELECTRIC STARTING SYSTEM 8 7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 395: ...elay 10 Starter motor 11 Relay unit 12 Starting circuit cut off relay 14 Sidestand switch 62 Right handlebar switch 65 Engine stop switch 66 Start switch 67 Gear position sensor 69 Left handlebar switch 72 Clutch switch 94 Ignition fuse 95 Engine ground 96 Battery negative lead ...

Page 396: ...ral position 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 con...

Page 397: ...ER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Gear position sensor 11 Start switch 12 Starter relay 13 Starter motor 14 Battery negative lead 15 Engine ground ...

Page 398: ...echarge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 118 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 48 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHEC...

Page 399: ...SITION SENSOR on page 8 127 Replace the gear position sensor 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the right handlebar switch 14 Check the entire starting sy...

Page 400: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 401: ...CHARGING SYSTEM 8 14 2 AC magneto 3 Rectifier regulator 4 Main fuse 7 Battery 95 Engine ground 96 Battery negative lead ...

Page 402: ...o CHECKING AND CHARGING THE BATTERY on page 8 109 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 118 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 119 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DIA...

Page 403: ...CHARGING SYSTEM 8 16 ...

Page 404: ...LIGHTING SYSTEM 8 17 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 405: ...light 60 Meter light 69 Left handlebar switch 70 Dimmer switch 75 Front left turn signal position light 76 Front right turn signal position light 79 Headlight 80 Auxiliary light 81 Ground cord headlight 82 License plate light 84 Tail brake light 85 Headlight relay 91 Headlight fuse 92 Signal fuse 94 Ignition fuse 95 Engine ground 96 Battery negative lead ...

Page 406: ...place the bulb s and bulb socket s 2 Check the fuses Main headlight ignition signal and fuel injection system Refer to CHECKING THE FUSES on page 8 109 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 109 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the main switch...

Page 407: ...LIGHTING SYSTEM 8 20 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting system s wiring Replace the ECU or meter assembly ...

Page 408: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 409: ...ear display 56 Coolant temperature warning light 58 Left turn signal indicator light 59 Right turn signal indicator light 61 Oil level switch 62 Right handlebar switch 64 Front brake light switch 67 Gear position sensor 68 Turn signal relay 69 Left handlebar switch 71 Horn switch 73 Turn signal switch 74 Horn 75 Front left turn signal position light 76 Front right turn signal position light 77 Rea...

Page 410: ...system Refer to CHECKING THE FUSES on page 8 109 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 109 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or...

Page 411: ...CKING THE SWITCHES on page 8 105 Replace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the front turn signal position light bulbs rear turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 108 Replace the front tu...

Page 412: ...ar position sensor 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 115 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 120 Replace the oil level swit...

Page 413: ...place the coolant temperature sen sor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the ECU or meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 121 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Prope...

Page 414: ...SIGNALING SYSTEM 8 27 NG OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring Replace the meter assembly ...

Page 415: ...SIGNALING SYSTEM 8 28 ...

Page 416: ...COOLING SYSTEM 8 29 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 417: ...system fuse 20 ECU engine control unit 41 Coolant temperature sensor 86 Radiator fan motor relay 87 Right radiator fan motor fuse 88 Left radiator fan motor fuse 89 Right radiator fan motor 90 Left radiator fan motor 94 Ignition fuse 95 Engine ground 96 Battery negative lead ...

Page 418: ...lace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 121 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 113 Replace the radiator fan motor relay 6 Check the coolant temperature sensor Refer to CHEC...

Page 419: ...COOLING SYSTEM 8 32 ...

Page 420: ...FUEL INJECTION SYSTEM 8 33 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 421: ...Secondary injector 2 32 Secondary injector 3 33 Secondary injector 4 34 Air induction system solenoid 35 Intake funnel servo motor 36 Throttle servo motor 37 Steering damper solenoid 38 Speed sensor 39 Intake air temperature sensor 40 Crankshaft position sensor 41 Coolant temperature sensor 42 Intake air pressure sensor 43 Atmospheric pressure sensor 44 Cylinder identification sensor 45 Lean angle...

Page 422: ...n 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 the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main swi...

Page 423: ...g light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating depending on the condi...

Page 424: ... 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 engine Fault code No No fault code No Check and repair Refer to TROU...

Page 425: ...opwatch LCD 6 Set the engine stop switch to 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET switches TIP To decrease the selected diagnostic code number press the RESET switch 1 Press the RESET switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELE...

Page 426: ...rature Compare the actually mea sured intake air temperature with the meter display value D 06 Coolant temperature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the meter display value D 07 Vehicle speed pulse 0 999 Check that the number increases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped D...

Page 427: ...d OFF D 21 Gear position switch Shift the transmission Neutral ON In gear OFF D 60 EEPROM fault code display No history 00 History exists 01 04 Cylinder fault code If more than one cylinder is defective the display alter nates every two seconds to show all the detected cylin der numbers When all cyl inder numbers are shown the display repeats the same process D 61 Malfunction history code display ...

Page 428: ...e shown the display repeats the same process To reinstate set the engine stop switch from to D 70 Control number 0 254 Diag nostic code No Item Meter display Checking method D 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one sec ond intervals Illuminates the engine trouble warning light Check the spark five times Connect an ignition checker D 31 Cylinder 2 ignit...

Page 429: ...njector 3 Actuates the primary injector 3 five times at one second intervals Illuminates the engine trouble warning light Check the operating sound of the injector 3 five times D 39 Primary injector 4 Actuates the primary injector 4 five times at one second intervals Illuminates the engine trouble warning light Check the operating sound of the injector 4 five times D 40 Secondary injector 1 Actuat...

Page 430: ...erating sound of the air induction system solenoid five times D 50 Fuel pump relay Actuates the fuel pump relay five times at one second intervals Illuminates the engine trouble 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 pump relay five times D 51 Radiator fan moto...

Page 431: ...e connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the...

Page 432: ...eplace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and che...

Page 433: ...spection procedure Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 117 Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 12 Symptom Normal signals are not received from the crankshaft position sen sor Fail safe action Engine startup Impossible Riding Impossible D...

Page 434: ...ck the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indica...

Page 435: ...or inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 125 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 13 Symptom Open or short circuit of intake air pressure sensor lead Fail safe action Engine startup Possible Ridi...

Page 436: ...r pressure sen sor hose is damaged discon nected clogged twisted or bent Repair or replace the sensor hose Starting the engine and oper ating it at idle Fully close the throttle and check the fault recovery 2 Intake air pressure sensor malfunction Check in the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m abov...

Page 437: ...ire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the ma...

Page 438: ...of power supply line 0 V Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 01 D 13 D 01 Meter display Throttle position sensor signal 1 12 21 fully closed position 97 106 fully opened position Checking method Check with throttle v...

Page 439: ... indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 15 Symptom Open or short circuit of throttle position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 01 D 13 D 01 Meter display Throttle position sensor signal 1 12 21 fully closed posi...

Page 440: ...k the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of main swi...

Page 441: ...ded No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Symptom Open or short circuit of ECU input line Blue Yellow lead Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitor ing code No D 20 Meter display Sidestand switch ON stand retracted OFF stand extended Checking method Set on off the sidestan...

Page 442: ...re the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Intake air pressure sensor malfunction Check in the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 3000 m above sea...

Page 443: ...o fault code indicated Recovered Fault code indicated Check the next step 3 ECU malfunction Replace the ECU Fault code No 20 Symptom When the main switch is ON there is a big difference in voltage value of the intake air pressure sensor and atmospheric pressure sensor Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No D 03 D 02 D 03 Meter display Displays the i...

Page 444: ...or connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recov ered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circuit Replace the wire harness Black Blue Black Blue Green White Green White Place the main switch to the ON position and check the f...

Page 445: ...code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the...

Page 446: ...ng method Compare the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of atmospheric pressure sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire h...

Page 447: ... the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 1000 m above sea level Approx 90 kPa 2000 m above sea level Approx 80 kPa 3000 m above sea level Approx 70 kPa Incorrect indication Sensor malfunction Replace the atmospheric pressure sen sor Sensor inspection procedure Refer to CHECKING THE ATMOSPHERIC PRES SURE SENSOR on page 8 124 Place the main switch ...

Page 448: ... code indicated Recovered Fault code indicated Check the next step 3 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Either start and warm up the engine and then racing it or reset it with diagnostic code 63 No fault code indi...

Page 449: ... job Sensor inspection proce dure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch is first turned OFF No fault code indicated Recovered Fault code indicated Check the next step 2 Sensor installation status Check for a loose mounting pinched mounting or sensor mounting direction up...

Page 450: ...on coil five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the spark five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking P...

Page 451: ...en check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil malfunction Check the resistance of igni tion coil 1 Refer to CHECKING THE IGNITION COILS on page 8 116 Ignition coil inspection method Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code in...

Page 452: ...heck the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approximately 5 seconds Then check the f...

Page 453: ...park five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds...

Page 454: ...nds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil malfunction Check the resistance of igni tion coil 3 Refer to CHECKING THE IGNITION COILS on page 8 116 Ignition coil inspection method Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault c...

Page 455: ...ck the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approximately 5 seconds Then check the fau...

Page 456: ... Code No 33 If not ignited replace the defective ECU Fault code No 36 Symptom Ignition coil 4 primary lead malfunction Fail safe action Engine startup Possible depending on the number of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 33 Meter display Actuates the cylinder 4 ignition coil five times at one second inter vals Illuminates...

Page 457: ...f the primary injector 3 five times D 39 Actuator oper ation Actuates the primary injector 4 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 4 five times Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Locate the malfunction Check in the diagnostic mode Code ...

Page 458: ...n the number of failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 36 D 37 D 38 D 39 D 36 Actuator oper ation Actuates the primary injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 1 five times D 37 Actuator oper ation Actuates the p...

Page 459: ... No D 36 D 37 D 38 D 39 D 36 Actuator oper ation Actuates the primary injector 1 five times at one second intervals Illuminates the engine trouble warning light Checking method Check the operating sound of the primary injector 1 five times D 37 Actuator oper ation Actuates the primary injector 2 five times at one second intervals Illuminates the engine trouble warning light Checking method Check t...

Page 460: ...es at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 3 five times D 43 Actuator oper ation Actuates the secondary injector 4 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 4 five times Item components and proba...

Page 461: ... failed cylin ders Riding Possible depending on the number of failed cylinders Diagnostic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary i...

Page 462: ...tes the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary injector 2 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 2...

Page 463: ...stic monitor ing code No D 40 D 41 D 42 D 43 D 40 Actuator oper ation Actuates the secondary injector 1 five times at one second inter vals Illuminates the engine trouble warning light Checking method Check the operating sound of the secondary injector 1 five times D 41 Actuator oper ation Actuates the secondary injector 2 five times at one second inter vals Illuminates the engine trouble warning ...

Page 464: ...en rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the harness Rotate the main switch to the O...

Page 465: ... Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 41 Symptom Open or short circuit of lean angle sensor lead Fail safe action Engine startup Impossible Riding Impossible Diagnostic monitor ing code No D 08 Meter display Lean angle sensor 0 4 1 4 upright 3 7 4 4 overturned Checking method Remove the lean angle sensor and incline more than 45 degrees Item comp...

Page 466: ...revented from rotating B Fail safe action Engine startup Possible Riding Possible Diagnostic monitoring code No D 21 Gear position sensor Meter display Gear position switch ON neutral OFF in gear Checking method Shift the transmission Checkpoints Inspection method Locate the malfunction Check in the diagnostic mode Code No 07 Rotate the rear wheel and make sure that the indication value increases ...

Page 467: ...or repair replace the wire harness Start the engine and check the connection of the coupler is secure Ride on the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circuit Replace the wire harness Black Blue Black Blue Blue Blue White Yellow White Yellow...

Page 468: ...nect or repair the coupler Start the engine and check the secure connection of the coupler Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of leads between gear position sensor and relay unit coupler Open short circuit Replace the wire harness Sky blue Sky blue Start the e...

Page 469: ...f relay unit cou pler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start and idle the engine for approximately 30 seconds Then check the fault code indication No fault indicated Recov ered Fault code indicated Check the next step 2 Connection of main harness ECU...

Page 470: ...1 02 indication CO concentration adjusted for cylinder 2 03 indication CO concentration adjusted for cylinder 3 04 indication CO concentration adjusted for cylinder 4 Checking method Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Locate the malfunction Diagnostic mode Code No 60 00 indication Normal status 01 indication CO concentra tion adjusted for cyl...

Page 471: ...h is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 04 is indicated in Diagnostic mode Code No 60 EEP ROM data error for adjustment of CO concentra tion of cylinder 4 Change the CO concentra tion of cylinder 4 and rewrite in EEP ROM After this adjustme...

Page 472: ...main switch Red Red Between the main switch and ignition fuse Brown Blue Brown Blue Between the ignition fuse and ECU Red White Red White Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Battery malfunction Check the battery voltage Refer to CHECKING AND CHARGING THE BATTERY on pa...

Page 473: ...open D 15 Meter display Accelerator position sensor signal 2 10 24 fully closed position 95 109 fully opened position Checking method Check with throttle grip fully closed Check with throttle grip fully open Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of accelerator position sensor coupler Check the connection of the coupler is secure Remov...

Page 474: ...ult code indicated Recovered Fault code indicated Check the next step Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully op...

Page 475: ...n of power supply line 0 V Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 fully closed position 97 107 fully opened position Checking method Check with th...

Page 476: ...lt code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 59 Symptom Open or short circuit of accelerator position sensor lead Fail safe action Engine startup Possible under certain conditions Riding Possible under certain conditions Diagnostic monitor ing code No D 14 D 15 D 14 Meter display Accelerator position sensor signal 1 12 22 full...

Page 477: ...ocking Poor connection Connect it securely or replace the har ness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Check the ETV Electronic Throttle Valve fuse Abnormality Replace the ETV Electronic Throttle Valve fuse Place the main switch to the ON position and check the fault code indicatio...

Page 478: ... Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of main harness ECU coupler Check the connection of the co...

Page 479: ...ode indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 70 Symptom Engine has been left idling The ECU automatically stops the engine after 20 minutes if it is left idling Fail safe action Engine startup Possible Riding Possible Diagnostic monitor ing code No Meter display Checking method Item components and probable...

Page 480: ...Connection of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harne...

Page 481: ...rness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circ...

Page 482: ...f main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or s...

Page 483: ...tion of main harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Ope...

Page 484: ...FUEL PUMP SYSTEM 8 97 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 485: ...tch 4 Main fuse 7 Battery 8 Fuel injection system fuse 11 Relay unit 13 Fuel pump relay 15 Fuel pump 20 ECU engine control unit 62 Right handlebar switch 65 Engine stop switch 94 Ignition fuse 95 Engine ground 96 Battery negative lead ...

Page 486: ... fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 109 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 105 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHE...

Page 487: ...FUEL PUMP SYSTEM 8 100 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 97 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 488: ...ELECTRICAL COMPONENTS 8 101 EAS27972 ELECTRICAL COMPONENTS ...

Page 489: ... 4 Ignition coil 5 Battery 6 Fuse box 7 Main fuse 8 Fuel injection system fuse 9 Starter relay 10 Rear brake light switch 11 Gear position sensor 12 Sidestand switch 13 O2 sensor 14 Speed sensor 15 Oil level switch 16 Radiator fan motor 17 Rectifier regulator 18 Horn 19 Steering damper ...

Page 490: ...ELECTRICAL COMPONENTS 8 103 ...

Page 491: ...Intake air pressure sensor 6 Intake funnel servo motor 7 Fuel pump 8 Relay unit 9 Lean angle sensor 10 Coolant temperature sensor 11 Crankshaft position sensor 12 Throttle servo motor 13 Throttle position sensor 14 Accelerator position sensor 15 Radiator fan motor relay 16 ECU engine control unit 17 Cylinder identification sensor ...

Page 492: ...ELECTRICAL COMPONENTS 8 105 EAS27980 CHECKING THE SWITCHES ...

Page 493: ...Horn switch 2 Clutch switch 3 Main switch 4 Dimmer switch 5 Turn signal switch 6 Sidestand switch 7 Gear position sensor 8 Oil level switch 9 Front brake light switch 10 Engine stop switch 11 Start switch 12 Rear brake light switch ...

Page 494: ...cket tester to 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 te...

Page 495: ...he bulbs 1 Remove 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 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 ...

Page 496: ... the fuse immediately 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 Rider seat Refer to GENERAL CHASSIS on page ...

Page 497: ...ry is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 ...

Page 498: ...ll contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illus...

Page 499: ...oltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on the battery This type o...

Page 500: ...n Out of specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery ter...

Page 501: ...tion Replace a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input voltage ...

Page 502: ...er 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 tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Sky blue White 4 No continuity Positive tester probe Sky blue W...

Page 503: ...e 2 Check Secondary coil resistance Out of specification Replace a Connect the pocket tester Ω 1 k to the ignition coil as shown b Measure the secondary coil resistance 3 Check Ignition spark gap Out of specification Replace a Connect the ignition checker 1 as shown Primary coil resistance 0 85 1 15 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red Black 1 Negat...

Page 504: ... LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the battery box 2 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect the test harness lean angle sen sor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resistance 248 372 Ω at 20 C 68 F Pock...

Page 505: ...ry lead otherwise the jumper lead may burn This check is likely to produce 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 wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil c...

Page 506: ... 1 b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the rectifier regulator output volt age EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn leads from the horn terminals Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester...

Page 507: ... harness 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance a Connect the pocket tester Ω 1 to the fuel sender terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Horn terminal 1 Negative tester probe Horn terminal 2 Oil level switch Maximum level position resis tance 484 536 Ω Minimum level position resis tance 114...

Page 508: ... from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Green White 1 Negative tester probe Black 2 Output voltage reading cycle 0 6 V...

Page 509: ...own b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Slowly heat the coolant then let it cool down to the specified temperature e Measure the coolant temperature sensor resistance EAS14B1086 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position s...

Page 510: ...lerator position sensor maximum resistance 3 Install Accelerator position sensor TIP When installing the accelerator position sen sor adjust its angle properly Refer to ADJUSTING THE ACCELERATOR POSI TION SENSOR on page 7 19 EAS14B1061 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter case Refer to AIR FILTER CASE on page 7 5 2 Check Throttle servo motor resistance Out of specification Replace...

Page 511: ...sure sen sor 5S7 3P 1 to the atmospheric pres sure sensor and wire harness as shown ECA14B1035 Pay attention to the installing direction of the test harness S pressure sensor 5S7 3P coupler a b Connect the digital circuit tester DCV to the test harness S pressure sensor 5S7 3P Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Yellow Red 1 Negative tester probe Light g...

Page 512: ...ltage reading should cycle from 0 8 V to 4 8 V to 0 8 V to 4 8 V EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sen sor 5S7 3P 1 to the intake air pressure sensor and wire harness as shown ECA14B1035 Pay attention to the installing direction of the test harness S pressure sensor 5...

Page 513: ...ot get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS14B1020 CHECKING THE STEERING DAMPER SOLENOID 1 Remove Left side cowling Refer to GENERAL CHASSIS on page 4 1 2 Check Steering damper solenoid resistance Out of specification Repl...

Page 514: ...be Black 2 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Result Neutral position Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a 1st position Continuity Positive tester probe White 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe Pink 3 Negative tester probe Sensor terminal c 3rd position Continuity Positive tes...

Page 515: ...e Out of specification Replace the fuel injector a Disconnect the fuel injector lead coupler from wire harness b Connect the pocket tester Ω 1 to the fuel injector coupler c Measure the fuel injector resistance Fuel injector resistance Primary injector Secondary injector 12 0 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative...

Page 516: ...ELECTRICAL COMPONENTS 8 129 ...

Page 517: ...DLING 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 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 518: ...ank overflow hose Clogged rollover valve for California Clogged fuel tank breather hose for Cali fornia Deteriorated or contaminated 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 ...

Page 519: ...gs EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly...

Page 520: ...e disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level 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 Incorre...

Page 521: ...ut headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired 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 ...

Page 522: ...er light 61 Oil level switch 62 Right handlebar switch 63 D Mode switch 64 Front brake light switch 65 Engine stop switch 66 Start switch 67 Gear position sensor 68 Turn signal relay 69 Left handlebar switch 70 Dimmer switch 71 Horn switch 72 Clutch switch 73 Turn signal switch 74 Horn 75 Front left turn signal position light 76 Front right turn signal position light 77 Rear left turn signal light...

Page 523: ......

Page 524: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 525: ...WIRING DIAGRAM YZFR1Y C ...

Page 526: ...WIRING DIAGRAM YZFR1Y C ...

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