Yamaha YZFR6V Service Manual Download

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SERVICE MANUAL

YZFR6V(C)

LIT-11616-19-78

2C0-28197-10

Summary of Contents for YZFR6V

Page 1: ...SERVICE MANUAL YZFR6V C LIT 11616 19 78 2C0 28197 10 ...

Page 2: ... Yamaha Motor Corporation U S A First edition December 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 19 78 ...

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

Page 4: ... 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 disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruc...

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

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

Page 7: ...YSTEM 1 3 YCC T Yamaha Chip Controlled Throttle 1 4 INSTRUMENT FUNCTIONS 1 7 IMPORTANT INFORMATION 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS 1 11 GASKETS OIL SEALS AND O RINGS 1 11 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND OIL SEALS 1 12 CIRCLIPS 1 12 CHECKING THE CONNECTIONS 1 13 SPECIAL TOOLS 1 14 ...

Page 8: ...E IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the passenger seat This information will be needed to order spare parts 1 1 ...

Page 9: ... control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine ope...

Page 10: ...hrottle valves 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 determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that...

Page 11: ... made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability Air intake volume is controlled according to the opera...

Page 12: ...l unit 5 ETV main CPU 32 bit 6 ETV sub CPU 16 bit 7 FI CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sensing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 18 A...

Page 13: ...sensor 5 Coolant temperature sensor 6 Neutral switch 7 Atmospheric pressure sensor 8 Throttle position for throttle cable pulley two signals 9 Throttle position for throttle valves two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map 18 Idle speed control 19 Calculated thro...

Page 14: ...ndicator light control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tach...

Page 15: ... the display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SELECT button The stopwatch digits will start flashing Release the SELECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stop watch 2...

Page 16: ...he display indicates an error code the ve hicle should be checked as soon as possible in order to avoid engine damage Display brightness and shift timing indicator light control mode This mode cycles through five control functions allowing you to make the following settings in the order listed below Display brightness This function allows you to adjust the bright ness of the displays and tachomete...

Page 17: ... min and 18000 r min From 10000 r min to 13000 r min the indi cator light can be set in increments of 500 r min From 13000 r min to 18000 r min the indicator light can be set in increments of 200 r min 1 Push the RESET button to select the de sired engine speed for activating the indicator light 2 Push the SELECT button to confirm the se lected engine speed The control mode changes to the shift ti...

Page 18: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

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

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

Page 21: ...ist provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 5 35 8 83 8 84 8 85 8 89 8 90 8 91 8 92 8 93 8 94 8 95 8 96 8 97 8 98 8 99 8 100 8 101 Valve lapper 90890 04101 Valve lapping tool YM...

Page 22: ... wrench 90890 01403 Spanner wrench YU 33975 3 27 4 58 Fork spring compressor 90890 01441 YM 01441 4 47 4 52 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 47 4 52 Damper rod holder 90890 01506 YM 01506 4 48 4 49 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 50 Tool name Tool No Illustration Reference pages ...

Page 23: ...6 Universal damping rod bleeding tool set YM A8703 4 51 4 52 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 58 Ring nut wrench 90890 01507 YM 01507 4 67 4 69 Damper rod holder 24 mm 90890 01328 YM 01328 4 67 4 68 Valve spring compressor 90890 04019 YM 04019 5 19 5 24 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 ...

Page 24: ...r ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 21 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 21 Valve spring compressor 90890 04109 5 24 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 28 5 29 5 31 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 28 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 29 5 31 5 57 Tool name Tool No Illus...

Page 25: ...pin puller set 90890 01304 Piston pin puller YU 01304 5 60 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Tool name Tool No Illustration Reference pages 0 40 0 30 0 35 0 25 0 20 0 15 0 10 0 05 0 03 0 50 YU 01304 YU 24460 01 YU 33984 ...

Page 26: ...U 03153 7 12 Fuel pressure adapter 90890 03176 YM 03176 7 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 13 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 92 Tool name Tool No Illustration Reference pages ...

Page 27: ...TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 31 COOLING SYSTEM DIAGRAMS 2 43 CABLE ROUTING 2 47 ...

Page 28: ...2040 mm 80 3 in Overall width 700 mm 27 6 in Overall height 1100 mm 43 3 in Seat height 850 mm 33 5 in Wheelbase 1380 mm 54 3 in Ground clearance 130 mm 5 12 in Minimum turning radius 3600 mm 141 7 in Weight With oil and fuel 182 0 kg 401 lb USA 183 0 kg 403 lb California Maximum load 193 kg 425 lb USA 192 kg 423 lb California ...

Page 29: ... amount 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 40 L 2 54 US qt 2 11 Imp qt With oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Oil cooler capacity including all routes 0 23 L 2 43 US qt 2 02 Imp qt Oil pressure hot 80 0 kPa 1300 r min 11 6 psi 1300 r min 0 80 kgf cm 1300 r min Oil filter Oil filter type Cartridge paper Oil pump Oil pump type Trocho...

Page 30: ...l pump Reduction ratio 85 41 29 31 1 939 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CR10EK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Volume 7 40 8 20 cm 0 45 0 50 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 22 500 22 521 mm 0 8858 0 8867 in Camshaft journal diameter 22 459 22 472 mm 0 88...

Page 31: ...9 mm 0 0047 0 0075 in Exhaust 0 16 0 23 mm 0 0063 0 0091 in Valve dimensions Valve head diameter A intake 26 90 27 10 mm 1 0591 1 0669 in Valve head diameter A exhaust 22 90 23 10 mm 0 9016 0 9094 in Valve face width B intake 1 410 2 550 mm 0 0555 0 1004 in Valve face width B exhaust 1 400 2 670 mm 0 0551 0 1051 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve ...

Page 32: ... 0 052 mm 0 0010 0 0020 in Limit 0 095 mm 0 0037 in Valve stem runout 0 040 mm 0 0016 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in Valve spring Free length intake 37 47 mm 1 48 in Limit 35 60 mm 1 40 in Free length exhaust 37 67 mm 1 48 in Limit 35 79 mm 1 42 in ...

Page 33: ... 66 975 66 990 mm 2 6368 2 6374 in Height H 10 0 mm 0 39 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043 mm 0 5922 in Piston pin outside diameter 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 00007 0 00068 in Piston ring Top ring Ring type B...

Page 34: ...0 48 25 mm 1 898 1 900 in Cylinders 3 and 4 47 90 47 95 mm 1 886 1 888 in Width B 268 80 270 00 mm 10 58 10 63 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 Small end free play F 0 32 0 50 mm 0 01 0 02 in Journal oil clearance using plastigauge 0 020 0 044 mm 0 0008 0 0017 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Clutch Clutch ty...

Page 35: ...ut limit 0 02 mm 0 0008 in Drive axle runout limit 0 02 mm 0 0008 in Shifting mechanism Shift mechanism type Shift drum Shift fork guide bar bending limit 0 050 mm 0 0020 in Shift fork thickness 5 760 5 890 mm 0 2268 0 2319 in Shift fork thickness 5 795 5 868 mm 0 2281 0 2310 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 2C0 DENSO Maxim...

Page 36: ... V Intake air pressure sensor output voltage 3 15 4 15 V Atmospheric pressure sensor output voltage 3 15 4 15 V Idling condition Engine idling speed 1250 1350 r min Intake vacuum 20 0 kPa 5 9 inHg 150 mmHg Water temperature 95 0 105 0 C 203 00 221 00 F Oil temperature 82 92 C 180 198 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in Air induction system Reed valve bending limit 0 4 mm 0 016 in So...

Page 37: ... Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D209F PT Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model DUNLOP D209PT 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 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 193 kg 198 425 lb US...

Page 38: ...0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 18 mm 1 50 in Recommended fluid DOT 4 Steering Steering head tension 200 500 g Steering bearing type Angular bearing Lock to lock angle left 25 0 Lock to lock angle right 25 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fork...

Page 39: ... 0 0 60 0 mm 0 00 2 36 in Optional spring available No Enclosed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm 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 525V8 DAIDO Link quantity 114 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 15 link length limit 239 3 mm 9 42 in ...

Page 40: ...rd output 14 0 V 420 W 5000 r min Stator coil resistance 0 12 0 18 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH678 11 SHINDENGEN Regulated voltage DC 14 1 14 9 V Rectifier capacity 22 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Manufacturer GS YUASA Ten hour rate amperage 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage ...

Page 41: ... 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768109 A JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω at 20 C 68 F Performance 105 113 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Built in self canceling device No Turn signal bli...

Page 42: ...urer ACM33211M05 MATSUSHITA Fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Fuel injection system fuse 15 0 A Backup fuse 7 5 A Electric throttle valve fuse 7 5 A Reserve fuse 15 0 A Reserve fuse 10 0 A Reserve fuse 7 5 A Reserve fuse 15 0 A ...

Page 43: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 44: ...tle body joint bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Connecting rod nut 1st M7 8 15 Nm 1 5 m kg 11 ft lb See NOTE Connecting rod nut final M7 8 Specified angle 175 185 See NOTE Generator rotor bolt M12 1 70 Nm 7 0 m kg 50 ft lb Timing chain tensioner bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Water pump ...

Page 45: ...2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt front side M6 1 8 Nm 0 8 m kg 5 8 ft lb EXUP valve pulley cover bolt rear side M6 2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve nut M6 1 7 Nm 0 7 m kg 5 1 ft lb Crankcase bolt M8 2 See NOTE l 115mm 4 53 in Crankcase bolt M8 8 See NOTE l 85 mm 3 35 in Crankcase bolt M8 2 24 Nm 2 4 m kg 17 ft lb l 65 mm 2 56 in Crankcase bolt M6 15 10 Nm 1 0 m kg 7 2 ft ...

Page 46: ... 8 7 ft lb Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Crankcase stud bolt M10 10 See NOTE Pressure plate bolt M6 6 8 Nm 0 8 m kg 5 8 ft lb Clutch boss nut M20 1 115 Nm 11 5 m kg 85 ft lb Stake Clutch boss plate stud bolt M8 6 25 Nm 2 5 m kg 18 ft lb Drive sprocket nut M20 1 85 Nm 8 5 m kg 61 ft lb Stake Main axle screw M6 3 12 Nm 1 2 m kg 8 7 ft lb Stake Shift drum retainer bolt...

Page 47: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence Crankcase tightening sequence 8 6 2 4 10 9 3 1 5 7 12 11 2 6 9 8 1 4 3 5 7 10 13 25 26 14 20 12 21 11 15 19 18 16 28 27 17 24 23 22 ...

Page 48: ...w front and rear M8 3 5 Nm 0 5 m kg 3 6 ft lb Front brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brake caliper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Rear brake caliper bolt M12 1 27 Nm 2 7 m kg 19 ft lb Rear brake pad pin M10 1 17 Nm 1 7 m kg 12 ft lb Rear brake screw plug 1 2 Nm 0 2 m kg 1 4 ft lb Handlebar pinch bolt M8 2 32 Nm 3 2...

Page 49: ... Rear shock absorber assembly upper nut M12 1 44 Nm 4 4 m kg 32 ft lb Rear shock absorber assembly lower nut M12 1 40 Nm 4 0 m kg 29 ft lb Rear shock absorber assembly spacer bolt M22 1 16 Nm 1 6 m kg 11 ft lb Rear shock absorber assembly bracket nut M14 1 52 Nm 5 2 m kg 37 ft lb Swingarm pivot shaft M32 1 16 Nm 1 6 m kg 11 ft lb Swingarm pivot shaft ring nut M32 1 95 Nm 9 5 m kg 68 ft lb Swingarm...

Page 50: ...der bolt M6 2 5 Nm 0 5 m kg 3 6 ft lb Radiator bracket and radiator bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator bracket and frame bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator outlet hose holder bolt M10 1 13 Nm 1 3 m kg 9 4 ft lb Coolant reservoir bolt M6 2 5 Nm 0 5 m kg 3 6 ft lb Front cowling assembly bolt M6 4 13 Nm 1 3 m kg 9 4 ft lb Seat lock plate bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rider seat ...

Page 51: ...ower ring nut 1 First tighten the lower ring nut to approximately 52 Nm 5 2 m kg 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 14 Nm 1 4 m kg 10 ft lb with a torque wrench NOTE Lower bracket pinch bolt Tighten each bolt to 23 Nm 2 3 m kg 17 ft lb in the order pinch bolt 1 pinch bolt 2 pinch bolt 1 4 1 3 2 1 2 ...

Page 52: ... inner and outer and oil pump housing Oil strainer screen inside oil strainer Oil strainer gasket Oil nozzle O ring Starter clutch idle gear shaft Starter clutch roller and starter clutch idle gear outer surface Primary driven gear inner surface Clutch pull rod Transmission gears wheel and pinion and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Cylinder head c...

Page 53: ...ATION POINTS AND LUBRICANT TYPES 2 26 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 54: ...Swingarm dust cover lips Swingarm pivot shaft nut Oil seals rear shock absorber relay arm and connecting arm 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 rod pivoting point Shift pedal pivoting point Brake pedal shaft pivoting p...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 6 5 4 3 2 1 11 12 13 14 10 9 7 8 ...

Page 56: ...ND DIAGRAMS 2 30 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil filter 5 Oil cooler 6 Main gallery 7 Oil nozzle 8 Timing chain tensioner 9 Intake camshaft 10 Exhaust camshaft 11 Oil pipe 12 Main axle 13 Shift fork 14 Drive axle ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Ventilation chamber cover 2 Relief valve 3 Ventilation chamber oil drain pipe 4 Oil cooler ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2 3 4 8 7 6 5 ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Oil check bolt 5 Oil strainer 6 Ventilation chamber oil drain pipe 7 Oil pipe 8 Oil pump ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 2 3 4 5 ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil cooler 2 Oil filter 3 Oil pipe 4 Oil pump 5 Oil strainer ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 5 4 3 2 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Oil pump 3 Oil pipe 4 Ventilation chamber oil drain pipe 5 Relief valve ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 3 1 2 5 4 ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil nozzle ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 1 3 2 ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil pipe 2 Main axle 3 Drive axle ...

Page 69: ...COOLING SYSTEM DIAGRAMS 2 43 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 44 1 Radiator inlet hose 2 Radiator inlet pipe 3 Thermostat outlet hose 4 Radiator ...

Page 71: ...COOLING SYSTEM DIAGRAMS 2 45 A A 2 1 3 4 5 6 7 8 6 13 8 9 15 14 9 10 11 12 ...

Page 72: ... Coolant reservoir 4 Radiator 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Radiator outlet pipe 8 Water jacket joint inlet hose 9 Water pump outlet pipe 10 Water pump inlet hose 11 Water pump outlet hose 12 Water pump 13 Water jacket joint 14 Oil cooler 15 Oil cooler inlet hose ...

Page 73: ...CABLE ROUTING 2 47 EAS20430 CABLE ROUTING A A A B C D E F G H I J 1 2 3 4 5 6 7 8 8 9 10 10 11 11 13 14 15 16 17 18 12 ...

Page 74: ...he end of the plastic locking tie outward and then cut off the excess end of the tie to 2 10 mm 0 08 0 39 in B Be sure to position the plastic locking tie above where the horn leads branch off from the other leads C 40 50 mm 1 57 1 97 in D Pass the throttle cables through the guide on the lower bracket making sure to route the decelerator cable above the accelerator cable as shown in the illustrat...

Page 75: ...CABLE ROUTING 2 49 1 2 3 3 4 4 4 5 5 6 7 8 9 10 11 12 13 14 14 15 15 16 15 16 17 18 19 19 20 20 21 21 22 23 24 25 26 27 A B P C D E F G H I K J L M N O 60 A A B B D D C A A B B D D C Q ...

Page 76: ...oir breather hose and clutch cable and then fasten them with the holder making sure to align the top of the holder with the bottom edge of the white paint mark on the cable G Fasten the clutch cable to the radiator outlet hose with the plastic band making sure to position the band between the screw clamp and the hose protector Install the plastic band with its buckle positioned toward the rear of ...

Page 77: ...CABLE ROUTING 2 51 C C B B B C C A A B B A C M N D H I J K L 1 2 3 4 5 6 6 7 7 8 10 11 12 13 9 8 14 6 7 13 14 E F G ...

Page 78: ... leads F Fasten the fuel tank drain hose and fuel tank breather hose except for California with the holder making sure to fasten the hoses below the holder on the engine G 30 50 mm 1 18 1 97 in H Pass the fuel tank drain hose fuel tank breather hose except for California and sidestand switch lead through the guides on the sidestand shield making sure to route the lead to the inside of the hoses I ...

Page 79: ...ABLE ROUTING 2 53 A A A B B A A B C D E F G H I J K L M N O E P E Q W X R V U T S S 1 2 3 4 5 7 6 7 6 8 8 9 10 10 11 11 12 13 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28 29 30 31 32 32 45 135 B B ...

Page 80: ...or lead and crankshaft position sensor lead under the wire harness K Insert the projection on the plastic locking tie that is fastened around the wire harness into the hole in the frame L Pass the neutral switch lead between the frame and the engine M To the ECU N Install both the engine ground lead terminal and the negative battery lead terminal to the crankcase with the bolt Make sure that the o...

Page 81: ...CABLE ROUTING 2 55 A 3 1 2 3 C B ...

Page 82: ...se A Pass the throttle cables between the front fork and the front brake hose B When installing the guide on the lower bracket be sure to pass the front brake hose through it C Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder ...

Page 83: ...CABLE ROUTING 2 57 4 5 7 8 9 11 13 14 12 10 15 16 11 16 6 A C E B D 5 6 10 12 16 1 2 3 ...

Page 84: ...se fuel tank to hose joint 10 Fuel hose primary injector fuel rail to secondary injector fuel rail 11 Intake air pressure sensor lead 12 Sub wire harness 3 13 Canister purge hose throttle body 2 to 3 way joint for California only 14 Atmospheric pressure sensor lead 15 Sub wire harness 2 16 Intake air pressure sensor hose A Face the ends of the clamp rearward B Route the sub wire harness 3 to the l...

Page 85: ...CABLE ROUTING 2 59 F F C C E E D D A A G G B B A B C E F D G H I J K 1 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 12 16 1 2 2 3 3 5 6 7 6 7 9 10 13 14 15 17 L 1 14 17 13 10 15 A A B B C C D D E E F F G G ...

Page 86: ...l hazard relay lead or relay unit lead over the front of the battery box or the damper E Pass the negative battery lead between the battery band and the battery F Pass the plastic band through the hole in the rib on the rear lower cowling from the front and then fasten the turn signal light couplers and license plate light connectors with the band Place the end of the plastic band between the rear...

Page 87: ...EM 3 16 CHECKING THE CANISTER for California only 3 16 ADJUSTING THE EXUP CABLES 3 16 CHECKING THE COOLANT LEVEL 3 18 CHECKING THE COOLING SYSTEM 3 18 CHANGING THE COOLANT 3 19 CHASSIS 3 21 ADJUSTING THE FRONT DISC BRAKE 3 21 ADJUSTING THE REAR DISC BRAKE 3 21 CHECKING THE BRAKE FLUID LEVEL 3 22 CHECKING THE FRONT BRAKE PADS 3 22 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSES 3 2...

Page 88: ...34 LUBRICATING THE SIDESTAND 3 34 LUBRICATING THE REAR SUSPENSION 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 REPLACING THE HEADLIGHT BULBS 3 35 ADJUSTING THE HEADLIGHT BEAMS 3 35 ...

Page 89: ...r 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 and adjust valve clear ance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhaust system Check for leakag...

Page 90: ...vot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leakage Replace if necessary 18 Shock absorber assembly Check operation and for oil leakage Replace if necessary 19 Rear suspension l...

Page 91: ...ing in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or dama...

Page 92: ... THROTTLE BODIES on page 7 8 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Radiator Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Refer to CAMSHAFTS on page 5 7 3 Remove Pickup rotor cover 1 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC m...

Page 93: ...er the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measured valve clearance...

Page 94: ... Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts tim ing chain and camshaft caps NOTE Refer to CAMSHAFTS on page 5 7 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Turn the crankshaft clockwise several full turns to seat the parts ...

Page 95: ...tle body has a bypass air screw with a white paint mark use the one with the lowest vacuum pressure as the standard After each step rev the engine two or three times each time for less than a second and check the synchronization again If an air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throttle body NOTE The difference in vacuum pressure between two throttle bodie...

Page 96: ... 3 8 10 Install Caps Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchroniza tion should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play a Loosen...

Page 97: ...hickness gauge Out of specification Regap 7 Install Spark plugs Ignition coils NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Install Air induction system solenoid Refer to AIR INDUCTION SYSTEM on page 7 15 Canister for California only Refer to THROTTLE BODIES on page 7 8 Air filter case Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 ...

Page 98: ...sion pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Refer to the following table 7 Install Spark plugs Ignition coils 8 Install Radiator Refer to RADIATOR on page 6 1 Bottom cowlings Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place th...

Page 99: ...off 2 Remove Left lower side cowling Left bottom cowling Refer to GENERAL CHASSIS on page 4 1 3 Place a container under the engine oil drain bolt 4 Remove Engine oil filler cap 1 5 Remove Engine oil drain bolt 1 along with the gasket 6 Drain Engine oil completely from the crankcase 7 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the shift arm 1 b Pull ...

Page 100: ... along with the gasket 10 Fill Crankcase with the specified amount of the recom mended engine oil 11 Install Engine oil filler cap 12 Start the engine warm it up for several min utes and then turn it off 13 Check Engine for engine oil leaks 14 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 10 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the min...

Page 101: ...ions Out of specification Adjust 7 Install Main gallery bolt 8 Install Left bottom cowling Left lower side cowling Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Oil pressure gauge set 90890 03120 Oil pressure adapter H 90890 03139 1 2 1 Oil pressure hot 80 0 kPa 1300 r ...

Page 102: ...ation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element CAUTION EC2C01007 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body synchronization leadin...

Page 103: ...030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel vacuum and breather hoses 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Fuel hoses 1 Vacuum hoses Overflow hose 2 Breather hose 3 except for California Cracks damage Replace Loose connection Connect properly CAUTION ECA14940 Make sure the fuel tank breather hose...

Page 104: ... 4 1 EAS21090 CHECKING THE CANISTER for California only 1 Remove Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 2 Check Canister Canister purge hoses 3 way joint Fuel tank breather hose rollover valve to canister Cracks damage Replace Refer to THROTTLE BODIES on page 7 8 3 Install Air filter case Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to...

Page 105: ... Loosen the locknuts 1 and 2 b Turn the adjusting bolt 3 in direction a or b until the specification c Tighten the locknut 1 to specification d Turn the adjusting bolt 4 in direction a or b until the specification e Tighten the locknut 2 to specification EXUP cable free play at the EXUP valve pulley 1 5 mm 0 06 in or less 1 b a Direction a Free play is increased Direction b Free play is decreased ...

Page 106: ...water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Exhaust pipe assembly Refer to ENGINE REMOVA...

Page 107: ... steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove Cool...

Page 108: ...water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check Coolant ...

Page 109: ... DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification WARNING EW2C01004 A soft or spongy feeling in the brake pedal ...

Page 110: ...rmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct ...

Page 111: ...holders 2 Loose connection Connect 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 29 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on jus...

Page 112: ... 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 NOTE The bleeding order of the front hydraulic brake system is the following 1 Front brake master cylinder 2 Front brake calipers 3 Front brake master cylinder d Place the other end of the hose into a con tainer e Slowly apply t...

Page 113: ... page 4 1 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no d...

Page 114: ...in solvents and the use of a coarse brush can damage 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 ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEERING...

Page 115: ...er washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 55 6 Measure Steering...

Page 116: ...G EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube 1 Damage scratches Replace Oil seal 2 Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 44 EAS21580...

Page 117: ... suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 0 Standard 1 Maximum 5 2 Current setting 3 Cap bolt collar 1 a b Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Stan...

Page 118: ...ion a or b c Align the desired position on the adjusting ring with the position indicator 2 Compression damping adjusting positions fast compression damp ing Minimum Distance c 8 mm 0 31 in Standard Distance c 10 mm 0 39 in Maximum Distance c 12 mm 0 47 in Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is s...

Page 119: ...imum 9 Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 20 click s out Standard 10 click s out Maximum 3 click s out With the adjusting screw fully turned in 1 a b 2 Direction a turn in Compression damping is increased suspension is harder Direction b turn out ...

Page 120: ...ar limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer Compression damping adjusting positions slow compression damping Minimum 24 click s out Standard 15 click s out Maximum 1 click s out With the adjusting screw fu...

Page 121: ...ng handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tir...

Page 122: ...f lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to metal moving parts of the pedals EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand E...

Page 123: ...d down 5 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer ...

Page 124: ... horizontally a Turn the adjusting screw 1 in direction a or b A Left headlight B Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right A Left headlight B Right headlight a 1 B b 1 a A b a b 1 B ...

Page 125: ... AND REPLACING THE REAR WHEEL SPROCKET 4 14 ASSEMBLING THE REAR WHEEL 4 15 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 15 CHECKING THE REAR BRAKE DISC 4 15 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 15 FRONT BRAKE 4 17 INTRODUCTION 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE PADS 4 23 REMOVING THE FRONT BRAKE CALIPERS 4 24 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 24 CHECKING ...

Page 126: ...ING THE HANDLEBARS 4 42 FRONT FORK 4 44 REMOVING THE FRONT FORK LEGS 4 47 DISASSEMBLING THE FRONT FORK LEGS 4 47 CHECKING THE FRONT FORK LEGS 4 48 ASSEMBLING THE FRONT FORK LEGS 4 49 INSTALLING THE FRONT FORK LEGS 4 53 STEERING HEAD 4 55 REMOVING THE LOWER BRACKET 4 58 CHECKING THE STEERING HEAD 4 58 INSTALLING THE STEERING HEAD 4 58 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORB...

Page 127: ...IVE 4 70 REMOVING THE DRIVE CHAIN 4 71 CHECKING THE DRIVE CHAIN 4 71 CHECKING THE DRIVE SPROCKET 4 72 CHECKING THE REAR WHEEL SPROCKET 4 72 CHECKING THE REAR WHEEL DRIVE HUB 4 72 INSTALLING THE DRIVE CHAIN 4 72 ...

Page 128: ...arks 1 Rider seat 1 2 Passenger seat 1 3 Fuel tank bracket 1 4 Negative battery lead 1 Disconnect 5 Positive battery lead 1 Disconnect 6 Battery band 1 7 Battery 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 7 6 4 5 3 2 4 ...

Page 129: ... turn signal light coupler 1 Disconnect 5 License plate light connector 2 Disconnect 6 License plate light assembly 1 7 Rear upper cowling damper plate 1 8 Tail brake light coupler 1 Disconnect 9 Tail brake light assembly 1 10 Right passenger footrest 1 11 Left passenger footrest 1 12 Rear lower cowling 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg...

Page 130: ...ition light coupler 2 Disconnect 5 Bottom cowling 2 6 Bottom cowling inner panel 2 7 Air intake duct 2 8 Rearview mirror 2 9 Headlight sub wire harness 1 coupler 1 Disconnect 10 Headlight sub wire harness 2 coupler 1 Disconnect 11 Front cowling assembly 1 For installation reverse the removal proce dure 5 4 5 4 7 3 R 13 Nm 1 3 m kg 9 4 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 6 7 2 1 6 3 8 11 10 9 4 8 1 2 ...

Page 131: ...stand so that the front wheel is elevated 1 Left reflector assembly 1 2 Right reflector assembly 1 3 Left front brake hose holder 1 4 Right front 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 Front wheel 1 11 Collar 2 12 Dust cover 2 ...

Page 132: ...FRONT WHEEL 4 5 13 Front brake disc 2 For installation reverse the removal proce dure Removing the front wheel and brake discs Order Job Parts to remove Q ty Remarks ...

Page 133: ...FRONT WHEEL 4 6 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 134: ...ver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller 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 ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIR...

Page 135: ...heel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the...

Page 136: ...o CHECKING THE FRONT BRAKE DISCS on page 4 22 EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 3 Lubricate Oil seal lips 4 Install Front wheel NOTE Install th...

Page 137: ...ht end of the front wheel axle is flush with the front fork If necessary manually push the front wheel axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front wheel axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the f...

Page 138: ...n a suitable stand so that the rear wheel is elevated 1 Rear brake caliper 1 2 Drive chain adjusting locknut 2 Loosen 3 Drive chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Rear wheel 1 8 Brake pad spring 1 9 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 139: ...et Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 1 4 Dust cover 1 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Dust cover 1 10 Collar 1 For installation reverse the removal proce dure ...

Page 140: ...REAR WHEEL 4 13 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 141: ...WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 7 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 7 ET2C01024 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake ...

Page 142: ... 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 8 ET2C01004 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 34 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a c...

Page 143: ...CHAIN SLACK on page 3 25 5 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Drive chain slack 35 0 45 0 mm 1 38 1 77 in T R Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE ...

Page 144: ...to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Reflector assembly 1 2 Brake hose holder 1 3 Front brake caliper 1 4 Brake pad clip 2 5 Brake pad pin 1 6 Brake pad spring 1 7 Front brake pad 2 For installation reverse the removal proce dure ...

Page 145: ...Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch connector 2 Disconnect 9 Front brake light switch 1 10 Front brake hose union bolt 1 11 Copper washer 2 12 Front brake hose 1 13 Front brake master cylinder holder 1 14 Front brake master cylinder 1 For installation reverse the removal proce dure LS T R 13 Nm 1 3 m ...

Page 146: ...ront brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure LS 1 3 2 1 T R 6 Nm 0 6 m kg 4 3 ft Ib New New ...

Page 147: ...ure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Reflector assembly 1 2 Brake hose holder 1 3 Front brake hose union bolt 1 4 Copper washer 2 5 Front brake hose 1 6 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 148: ...ve Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 149: ...ISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 4 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn t...

Page 150: ...e pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring NOTE The arrow mark a on the brake pad spring must point in the dire...

Page 151: ...re applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW2C01005 Do not loosen the bolts 3 a Blow compressed air into the brake hose joint opening a to force out the left side pistons from the brake caliper WARNING EWA13580 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake mast...

Page 152: ...ake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 47 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remov...

Page 153: ...4 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hoses 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1...

Page 154: ...ir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling ...

Page 155: ...FRONT BRAKE 4 28 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 a ...

Page 156: ... 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 2 5 Brake pad insulator 2 6 Rear brake pad 2 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 157: ...id reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure New New T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2...

Page 158: ...bling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure New New New LS 2 1 3 ...

Page 159: ...ts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 5 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 160: ... Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad shim 2 4 Brake pad insulator 2 5 Rear brake pad 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston seal 2 9 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 161: ...amage 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 22 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 5 Adjust Brake disc deflection Refer...

Page 162: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper...

Page 163: ...ke fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new ...

Page 164: ... the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic pa...

Page 165: ...amage Replace 4 Check Rear brake hose Brake fluid reservoir hose Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Rear brake hose ...

Page 166: ...por lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 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 22 5 Check Brake p...

Page 167: ...YSTEM on page 7 15 1 Left grip end 1 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 Disconnect 6 Clutch lever assembly 1 7 Right grip end 1 8 Throttle cable housing 2 9 Throttle cable 2 Disconnect 10 Throttle grip 1 T R 32 Nm 3 2 m kg 23 ft Ib LS T R 115 Nm 11 5 m kg 85 ft lb T R 13 Nm 1 3 m kg 9 4 ft Ib LS T R 26 Nm 2 6 m kg 19 ft Ib T R 5 Nm ...

Page 168: ...upler 2 Disconnect 21 Upper bracket 1 22 Handlebar pinch bolt 2 Loosen 23 Left handlebar 1 24 Right handlebar 1 For installation reverse the removal proce dure Removing the handlebars Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib LS T R 115 Nm 11 5 m kg 85 ft lb T R 13 Nm 1 3 m kg 9 4 ft Ib LS T R 26 Nm 2 6 m kg 19 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 169: ...curely support the vehicle so that there is no danger of it falling over 2 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Install the brake master cylinder holder with the UP mark a facing up Align the mating surfaces of the brake master cylinder holder with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 3 Install Right handlebar...

Page 170: ...c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 9 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer ...

Page 171: ...RONT WHEEL on page 4 4 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 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T ...

Page 172: ...egs 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Damper adjusting rod 1 5 Nut 1 6 Spacer 1 7 Fork spring 1 8 Spring seat 1 9 Outer tube 1 10 Dust seal 1 11 Oil seal clip 1 12 Oil seal 1 13 Washer 1 14 Damper rod assembly 1 T R 25 Nm 2 5 m kg 18 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 1 2 New 3 5 6 7 8 9 13 12 11 10 New New New 4 14 15 ...

Page 173: ...y reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks T R 25 Nm 2 5 m kg 18 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 1 2 New 3 5 6 7 8 9 13 12 11 10 New New New 4 14 15 ...

Page 174: ... THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Position the collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spac...

Page 175: ...damper rod assembly with the damper rod holder 1 5 Remove Oil seal clip 1 with a flat head screwdriver EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of...

Page 176: ...e the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to...

Page 177: ... 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 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 ...

Page 178: ...he fork oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Spring seat 1 Fork spr...

Page 179: ...rod l Install the washer and cap bolt and then fin ger tighten the cap bolt m Hold the nut and tighten the spring preload adjusting bolt 10 into the cap bolt to specifi cation WARNING EWA13670 Always use a new cap bolt O ring CAUTION EC2C01013 When tightening the spring preload adjust ing bolt 10 into the cap bolt be sure not to break the projections c on the collar 11 NOTE Hold the nut 4 using a ...

Page 180: ... 23 Nm 2 3 m kg 17 ft lb in the order pinch bolt 1 pinch bolt 2 pinch bolt 1 3 Tighten Cap bolt 1 Handlebar bolt 2 Handlebar pinch bolt 3 Upper bracket pinch bolt 4 4 Check Cable routing NOTE Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 47 5 Install Plastic locking tie 1 Plastic locking tie 2 NOTE Fasten the l...

Page 181: ...ORK 4 54 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 FRONT FORK LEGS on page 3 28 1 2 ...

Page 182: ... cover Refer to AIR INDUCTION SYSTEM on page 7 15 1 Rectifier regulator holder 1 2 Left coupler holder 1 3 Main switch coupler 2 Disconnect 4 Clutch cable 1 Disconnect 5 Left handlebar assembly 1 6 Right handlebar assembly 1 7 Horn connector 2 Disconnect 8 Horn 1 9 Front brake hose joint 1 LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2...

Page 183: ...ng 1 22 Lower bearing 1 23 Lower bearing inner race 1 24 Lower bearing dust seal 1 25 Upper bearing outer race 1 Removing the lower bracket Order Job Parts to remove Q ty Remarks LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 14 Nm 1 4 m kg 10 ft Ib T R 115 Nm 11 5 m kg 85 ft lb T R 5 Nm ...

Page 184: ...arts to remove Q ty Remarks LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 14 Nm 1 4 m kg 10 ft Ib T R 115 Nm 11 5 m kg 85 ft lb T R 5 Nm 0 5 m kg 3 6 ft Ib 12 13 14 15 16 1 3 2 7 20 17 4 8 18 10 9 11 5 19 21 25 26 22 23 24 6 ...

Page 185: ...eplace 3 Replace Bearings Bearing races a Remove the bearing race from the steering head pipe 1 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 new bearing races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set...

Page 186: ...teering stem nut 6 Install Front brake hose joint bracket 1 Lower bracket cover 2 Front brake hose joint 3 NOTE Make sure that the tab a on the front brake hose joint bracket contacts the side b of the front brake hose joint 7 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer to CA BLE ROUTING on pa...

Page 187: ...bsorber assembly lower nut Wash er Bolt 1 1 1 4 Rear shock absorber assembly bracket nut 1 5 Rear shock absorber assembly upper nut Bolt 1 1 6 Rear shock absorber assembly bracket 1 7 Rear shock absorber assembly 1 8 Spacer bolt 1 9 Relay arm nut Bolt Spacer 1 1 1 10 Relay arm 1 11 Spacer 1 12 Spacer 1 1 1 1 1 2 9 13 15 14 13 12 15 10 9 9 3 5 13 8 4 6 7 14 13 11 3 5 2 1 1 LS LS LS LS LS New New Ne...

Page 188: ...r shock absorber assembly Order Job Parts to remove Q ty Remarks 1 1 1 1 2 9 13 15 14 13 12 15 10 9 9 3 5 13 8 4 6 7 14 13 11 3 5 2 1 1 LS LS LS LS LS New New New New 13 3 T R 16 Nm 1 6 m kg 11 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 52 Nm 5 2 m kg 37 ft Ib T R 44 Nm 4 4 m kg 32 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib ...

Page 189: ...hole through the rear shock absorber at a point 50 mm 1 97 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 falling over NOTE Place the vehicle on a suitable stand...

Page 190: ... EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacer 2 Tighten Relay arm nut 3 Install Spacer bolt Rear shock absorber assembly Rear shock absorber assembly bracket 1 NOTE Be sure to fit the projection on either side of the rear shock absorber assembly bracket into the indentation in the frame Recommended lubricant Lithium soap based grease Installed depth of bearing a 4 5 mm 0...

Page 191: ...ing arms NOTE When installing the connecting arms lift up the swingarm 6 Tighten Connecting arm nuts T R Spacer bolt 16 Nm 1 6 m kg 11 ft lb T R Rear shock absorber assembly lower nut 40 Nm 4 0 m kg 29 ft lb T R Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 32 ft lb T R Rear shock absorber assembly bracket nut 52 Nm 5 2 m kg 37 ft lb T R Connecting arm nuts 40 Nm 4 0 m kg 29 ft lb 1 ...

Page 192: ...ng locknut 2 2 Drive chain puller 2 3 Drive chain adjusting bolt 2 4 Rear fender 1 5 Drive chain guard 1 6 Drive chain guide swingarm side 1 7 Drive chain 1 8 Swingarm pivot shaft nut 1 9 Washer 1 10 Swingarm pivot shaft ring nut 1 11 Washer 1 12 Swingarm pivot shaft 1 4 16 9 14 14 20 13 15 19 17 6 5 3 10 12 8 3 2 18 11 1 1 2 LS LS 20 19 7 LS LS New New LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 N...

Page 193: ...lation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 4 16 9 14 14 20 13 15 19 17 6 5 3 10 12 8 3 2 18 11 1 1 2 LS LS 20 19 7 LS LS New New LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 95 Nm 9 5 m kg 68 ft Ib ...

Page 194: ...If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 71 4 Remove Swingarm pivot shaft ring nut 1 NOTE Loosen the swingarm pivot shaft ring nut with the ring nut wrench 2 5 Remove Swingarm pivot shaft 1 NOTE Loosen the swingarm pivot shaft with the damp er rod holder 24...

Page 195: ...stall Swingarm pivot shaft 1 NOTE Tighten the swingarm pivot shaft with the damp er rod holder 24 mm 2 4 Install Swingarm pivot shaft ring nut 1 Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease Installed depth of bearing a 0 1 0 mm 0 0 04 in Installed depth of bearing b 4 0 mm 0 16 in Installed depth of oil seal c 1 0 mm 0 04 in 5 Swingarm 6 Swingarm pivot shaf...

Page 196: ...nut wrench 2 5 Install Swingarm pivot shaft nut NOTE Lubricate the swingarm pivot shaft nut threads and mating surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 T R Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 68 ft lb Ring nut wrench 90890 01507 YM 01507 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 2 1 ...

Page 197: ...tom cowling Refer to GENERAL CHASSIS on page 4 1 Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Drive sprocket cover 1 2 Drive sprocket nut 1 3 Washer 1 4 Drive chain guide drive sprocket side 1 5 Drive sprocket 1 6 Drive chain 1 For installation reverse the removal proce dure New LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib 1 5 4 3 2 6 ...

Page 198: ...es length b between pin outer sides 2 NOTE When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the...

Page 199: ... set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 14 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut St...

Page 200: ...CHAIN DRIVE 4 73 1 2 3 a a New ...

Page 201: ...CYLINDER HEAD 5 16 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 CHECKING THE VALVE LIFTERS 5 23 INSTALLING THE VALVES 5 23 GENERATOR AND STARTER CLUTCH 5 26 REMOVING THE GENERATOR 5 28 CHECKING THE STARTER CLUTCH 5 28 INSTALLING THE STARTER CLUTCH 5 28 INSTALLING THE GENERATOR 5 29 PIC...

Page 202: ...E OIL PAN 5 53 CHECKING THE OIL PUMP 5 53 CHECKING THE RELIEF VALVE 5 53 CHECKING THE OIL PIPES 5 54 CHECKING THE OIL STRAINER 5 54 ASSEMBLING THE OIL PUMP 5 54 INSTALLING THE OIL PAN 5 54 CRANKCASE 5 55 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 CHECKING THE OIL PIPE 5 57 CHECKING THE TIMING CHAIN 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 59 REMOVING THE C...

Page 203: ... 5 71 REMOVING THE TRANSMISSION 5 76 CHECKING THE SHIFT FORKS 5 76 CHECKING THE SHIFT DRUM ASSEMBLY 5 76 CHECKING THE TRANSMISSION 5 77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 77 INSTALLING THE TRANSMISSION 5 78 ...

Page 204: ...r 1 6 Gasket 1 7 O2 sensor 1 8 Exhaust pipe assembly 1 9 Gasket 4 10 Exhaust pipe assembly bracket left lower side 1 11 Exhaust pipe assembly bracket left upper side 1 LS LT 12 10 1 2 3 5 4 6 8 8 7 9 New LT T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 45 Nm 4 5 m kg 32...

Page 205: ...pipe assembly Order Job Parts to remove Q ty Remarks LS LT 12 10 1 2 3 5 4 6 8 8 7 9 New LT T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 13 16 14 15 3 2 T ...

Page 206: ... to ELECTRIC STARTER on page 5 33 Thermostat Refer to THERMOSTAT on page 6 7 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 9 Drive sprocket Refer to CHAIN DRIVE on page 4 70 1 Shift rod 1 2 Shift arm 1 3 Oil filter cartridge 1 4 Oil filter cartridge bolt 1 5 Crankcase breather hose 1 5 6 7 11 15 15 12 13 14 10 9 8 2 1 4 3...

Page 207: ...1 Disconnect 13 Clutch cable 1 Disconnect 14 Cylinder identification sensor coupler 1 Disconnect 15 Ignition coil coupler 4 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 5 6 7 11 15 15 12 13 14 10 9 8 2 1 4 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg ...

Page 208: ...r side 1 6 Engine mounting collar outside 1 7 Engine mounting collar inside 1 8 Engine mounting bolt rear upper side 1 9 Engine mounting nut rear lower side 1 10 Engine mounting collar outside 1 11 Engine mounting collar inside 1 12 Engine mounting bolt rear lower side 1 13 Engine 1 For installation reverse the removal proce dure 1 2 3 9 1011 5 6 7 1 13 2 3 4 4 8 12 T R 45 Nm 4 5 m kg 32 ft Ib T R...

Page 209: ...ass the drive axle through the drive chain when installing the engine 1 Do not fully tighten the bolts and nuts 2 Tighten Engine mounting nut rear lower side 6 Engine mounting nut rear upper side 7 Engine mounting bolts front left side 8 Engine mounting bolts front right side 11 3 Install Shift arm 1 NOTE Install the shift arm 1 with its punch mark a aligned with the notch b in end of the shift sh...

Page 210: ...cut off valve Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil 4 2 Spark plug 4 3 Cylinder identification sensor 1 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide upper side 1 For installation reverse the removal proce dure 2 1 4 6 3 6 6 5 New New LT LT LS T R 8 Nm 0 8 m kg 5 8 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib...

Page 211: ... gasket 1 4 Intake camshaft cap 3 5 Exhaust camshaft cap 3 6 Camshaft sprocket 2 7 Intake camshaft 1 8 Exhaust camshaft 1 9 Pin 2 10 Timing chain guide intake side 1 11 Timing chain guide exhaust side 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New 4 1 6 2 3 10 9 7 5 5 5 10 10 8...

Page 212: ...he camshaft lobes are turned away from each other 3 Remove Camshaft caps 1 CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 4 Remove Intake camshaft Exhaust camshaft NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 1 EAS23850 CHECK...

Page 213: ...s out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Intake A 33 725 33 875 mm 1 3278 1 3337 in Limit 33 675 mm 1 3258 in Intake B 25 225 25 325 mm 0 9931 0 9970 in Limit 25 175 mm 0 9911 in Exhaust A 32 925 33 075 mm 1 2963 1 3022 in Lim...

Page 214: ...ear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Remove Timing chain tensioner rod 1 Timing chain tensioner spring seat 2 Timing chain tensioner inner spring 3 Timing chain tensioner outer spring 5 Timing chain tensioner housing 6 NOTE Squeeze the timing chain tensioner clip 4 and then remove the timing chain tensioner springs and timing chain tensioner rod 2 Check T...

Page 215: ...ip while pushing the rod into the housing other wise the rod may be ejected c Hook the clip 4 to the timing chain tensioner rod 3 NOTE Hook the timing chain tensioner rod pin 5 to the center of the clip 4 After the installation check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation EAS24010 INSTALLING THE CAMSHAFTS 1 Align T...

Page 216: ... cam shaft points towards the right side of the en gine 4 Install Camshaft cap bolts CAUTION ECA13730 The camshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshafts will result NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out 5 Install Timing chain tensioner gasket 1 Timing chain tensioner 2 NOTE ...

Page 217: ... on the pickup rotor is aligned with the crankcase mating surface b Camshaft sprocket match mark c Make sure the marks on the camshaft sprockets are aligned with the edge of the cyl inder head d Out of alignment Adjust Refer to the installation steps above 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 10 Install Cylinder head cover gasket...

Page 218: ...TS on page 5 7 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 1 2 3 4 T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 42 Nm 4 2 m kg 30 ft lb T R 1st 30 Nm 3 0 m kg 22 ft lb 2nd 60 Nm 6 0 m kg 43 ft lb T R 18 Nm 1 8 m kg 13 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New New 8 T R 20 Nm 2 0 m kg 14 ft Ib E E E ...

Page 219: ...eposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To...

Page 220: ...nuts cap nuts and bolts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head cap nut 1st 30 Nm 3 0 m kg 22 ft lb Cylinder head cap nut final 60 Nm 6 0 m kg 43 ft lb T R Cylinder head bolt 12 Nm 1 2 m kg 8 7 ft lb 8 6 2 4 10 9 3 1 5 7 12 11 ...

Page 221: ...n page 5 15 1 Valve lifter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure 1 2 3 3 4 5 9 10 1 2 3 3 4 6 9 10 7 8 11 12 E New New M M E M M M M M ...

Page 222: ... 21 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spri...

Page 223: ...nd valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 ...

Page 224: ...minate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 041...

Page 225: ...l the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean of...

Page 226: ...ollowing procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant Free length intake 37 47 mm 1 48 in Limit 35 60 mm 1 40 in Free length exhaust 37 67 mm 1 48 in Limit 35 79 mm 1 42 in Installed compression spring force intake 166 00 190 00 N 37 32 42 71 lb 16 93 19 37 kgf Insta...

Page 227: ...lve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger b Smaller pitch Valve sp...

Page 228: ...VALVES AND VALVE SPRINGS 5 25 Each valve lifter and valve pad must be rein stalled in its original position ...

Page 229: ...E OIL on page 3 11 1 Stator coil assembly coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Stator coil assembly lead holder 1 6 Stator coil assembly 1 7 Starter clutch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor 1 10 Starter clutch 1 3 2 6 5 4 8 7 11 10 9 4 1 New New New LT LT E 9 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R ...

Page 230: ...reverse the removal proce dure Removing the generator and starter clutch Order Job Parts to remove Q ty Remarks 3 2 6 5 4 8 7 11 10 9 4 1 New New New LT LT E 9 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 70 Nm 7 0 m kg 50 ft lb E E ...

Page 231: ...tch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear 1 onto the gen erator rotor 2 and hold the generator rotor 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...

Page 232: ...rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt 3 Apply Sealant onto the stator coil assembly lead grommet T R Generator rotor bolt 70 Nm 7 0 m kg 50 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A a 1 New 1 2 3 Yamaha bond No 1215 90890...

Page 233: ...R AND STARTER CLUTCH on page 5 26 1 Clutch cable 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Pickup rotor cover 1 4 Pickup rotor cover gasket 1 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT LT 1 3 3 5 4 2 6 LS New New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg...

Page 234: ...ickup rotor align the groove a in the crankshaft with the projection b on the pickup rotor 2 Tighten Pickup rotor bolt 1 NOTE 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 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup coil rotor bolt 35 Nm 3 5 m kg 25 ft lb Sh...

Page 235: ...PICKUP ROTOR 5 32 ...

Page 236: ...on page 4 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Fuel tank Refer to FUEL TANK on page 7 1 Thermostat Refer to THERMOSTAT on page 6 7 1 Starter motor lead 1 2 Starter motor assembly 1 For installation reverse the removal proce dure 1 2 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 237: ...rks 1 O ring 1 2 Starter motor front cover 1 3 Lock washer 1 4 Oil seal 1 5 Bearing 1 6 Washer set 1 7 Starter motor yoke 1 8 Armature assembly 1 9 Gasket 2 10 Washer set 2 11 Brush holder along with the brushes 1 12 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 238: ... commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica u...

Page 239: ...SSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers ...

Page 240: ...on page 3 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Water pump breather hose 1 Disconnect 2 Clutch cable 1 Disconnect 3 Pull lever 1 4 Pull lever spring 1 5 Clutch cover 1 6 Clutch cover gasket 1 7 Dowel pin 2 For installation reverse the removal proce dure 5 2 6 7 1 3 4 7 LT New New LT New LS 7 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft...

Page 241: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure LS New New E 5 4 3 2 LS 1 ...

Page 242: ...e 1 1 6 Friction plate 2 7 black painting 7 Clutch plate 2 1 8 Clutch plate 3 6 9 Friction plate 3 1 purple painting 10 Clutch boss nut 1 11 Spring 3 12 Clutch boss 1 13 Clutch boss plate 1 14 Washer 1 15 Thrust washer 1 1 16 Spacer 1 1 2 3 4 5 6 6 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E 6 E E T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 ...

Page 243: ...rive chain guide 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 6 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 New LT LT LT LT LS E 6 E E T R 8 Nm 0 8 m kg 5 8 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 115 Nm 11 5 m kg 85 ft lb ...

Page 244: ...TION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch pl...

Page 245: ...ing the clutch plate s be sure to replace the clutch plate 1 first After replacing the clutch plate 1 if specifications cannot be met replace the clutch plate 2 EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutc...

Page 246: ...URE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the cl...

Page 247: ...nstall the chain onto the oil pump driven sprocket while installing the clutch housing onto the main axle Make sure that the oil pump drive chain passes through the oil pump drive chain guide 2 Install Clutch boss plate 1 Clutch boss 2 NOTE Fit the projections a on the clutch boss into the grooves b in the clutch boss plate 3 Install Springs 1 NOTE Stack the springs on top of each other making sur...

Page 248: ...plate with one of the three punch marks b in the clutch boss 8 Install Seat plate Clutch springs Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Dowel pins Clutch cover gasket Clutch cover 1 NOTE Position the pull rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply locking agent LOCTITE to the thr...

Page 249: ...er is facing up When installing the pull lever push it and check that its punch mark b aligns with the mark c on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 1 a New c 1 2 b a ...

Page 250: ...E REMOVAL on page 5 1 Clutch housing Refer to CLUTCH on page 5 37 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 Spacer 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 3 10 9 7 6 5 4 13 13 12 2 1 8 11 LS New New New LT E E T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 251: ...Bearing 2 For installation reverse the removal proce dure Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks 3 10 9 7 6 5 4 13 13 12 2 1 8 11 LS New New New LT E E T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 252: ...ar Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Shift shaft spring 2 NOTE Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring onto the shift shaft spring stopper Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift d...

Page 253: ...ER PUMP on page 6 9 Clutch housing Refer to CLUTCH on page 5 37 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Bottom cowling bracket 2 5 Oil pan 1 6 Oil pan gasket 1 7 Oil strainer 1 8 Oil strainer gasket 1 8 10 13 6 5 12 7 9 7 9 11 10 4 4 2 1 3 11 4 5 4 2 3 New New New New New New LS LS LS LS LT New New 10 E LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 ...

Page 254: ...verse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks 8 10 13 6 5 12 7 9 7 9 11 10 4 4 2 1 3 11 4 5 4 2 3 New New New New New New LS LS LS LS LT New New 10 E LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 255: ... Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump housing 1 8 Oil pump driven sprocket 1 For assembly reverse the disassembly pro cedure ...

Page 256: ... housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s 1 Inner rotor 2 Outer rotor 3 Oil pump housin...

Page 257: ...haft with the recommended lubricant 2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 53 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan ...

Page 258: ... pump drive chain guide Refer to CLUTCH on page 5 37 Oil pump assembly Refer to OIL PUMP on page 5 50 1 Timing chain 1 2 Dipstick 1 3 Neutral switch lead 1 4 Neutral switch 1 5 Ventilation chamber cover 1 6 Ventilation chamber cover gasket 1 7 Oil pipe 1 8 Oil baffle plate 1 1 11 4 3 2 11 6 10 1 8 9 7 5 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm ...

Page 259: ...g the crankcase Order Job Parts to remove Q ty Remarks 11 4 3 2 11 6 10 1 8 9 7 5 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib LS New New New New New LS LS LS LT LT LT LT 3 LT T R 12 Nm 1 2 m kg 8 7 ft Ib 4 ...

Page 260: ... 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 EAS25600 CHECKING THE OIL PIPE 1 Check Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS25620 CHECKING THE TIMING CHAIN Refer to CAMSHAFTS on page 5 7 EAS25640 ASSEMBLIN...

Page 261: ...55 mm bolts 15 22 27 M6 45 mm bolts 17 19 7 Tighten Crankcase bolts 1 10 Loosen all bolts following the tightening or der and then tighten to specification torque NOTE Tighten the bolts in the tightening sequence cast on the crankcase 8 Tighten Crankcase bolts 11 28 NOTE Tighten the bolts in the tightening sequence cast on the crankcase T R Crankcase bolt M8 115 mm M8 85 mm 1st 20 Nm 2 0 m kg 14 f...

Page 262: ...to CRANKCASE on page 5 55 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure New E New E New New New E M M T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd Specified angle 175 185 E 7 6 5 4 9 8 10 3 3 1 2 M M New ...

Page 263: ... put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of th...

Page 264: ...earance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder Bore 67 000 67 010 mm 2 6378 2 6382 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 T maximum of D1 or D2 maximum ...

Page 265: ...pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 5 mm 0 20 in Piston ring Top ring End gap installed 0 25 0 35 mm 0 0098 0 0138 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 70 0 80 mm 0 0276 0 0315 in Limit 1 00 mm 0 0394 in Oil ring End g...

Page 266: ... b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolt threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank ...

Page 267: ...pper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 2 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod left when the punch mark b on the pis ton is pointing up Refe...

Page 268: ...nd connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings one hand install the connecting rod assembly into the cyl inder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure the characters b on both the con necting rod and connecting rod cap are aligned 8 Tighten C...

Page 269: ...rther to reach the specified angle 175 185 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again CAUTION ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle NOTE On a hexagonal nut note th...

Page 270: ...ks Crankcase Separate Refer to CRANKCASE on page 5 55 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 59 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 1 2 3 E E E 4 New LS ...

Page 271: ...asure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION 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 crank shaft journal bearings must be installed in their original positions a Clean the cranks...

Page 272: ...f the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the cran...

Page 273: ...al upper bearings into the upper crankcase Crankshaft journal lower bearings into the lower crankcase NOTE Align the projections a on the crankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place ...

Page 274: ... assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 2 6 Spring 2 7 Shift fork guide bar 2 8 Shift fork L 1 9 Shift fork R 1 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 13 Oil pipe 1 14 Bearing 1 E E E E 12 11 7 13 5 6 7 6 10 5 4 9 8 1 2 3 15 14 LT LT E E LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E New T R 10 Nm 1 0 m kg 7 2 ft Ib 3 New...

Page 275: ...dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks E E E E 12 11 7 13 5 6 7 6 10 5 4 9 8 1 2 3 15 14 LT LT E E LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E New T R 10 Nm 1 0 m kg 7 2 ft Ib 3 New LS LS ...

Page 276: ... 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 Bearing housing 1 14 Bearing 1 15 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure M M M M E 1 2 3 4 5 8 9 6 7 10 13 14 15 12 11 New New ...

Page 277: ...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 16 Circlip 1 17 Washer 1 E M 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 20 M M M 7 New New New M M ...

Page 278: ...Collar 1 20 Bearing 1 21 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks E M 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 20 M M M 7 New New New M M ...

Page 279: ...ng 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 guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the s...

Page 280: ...ded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace ET2C01015 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be su...

Page 281: ...side and install it close to the right side end of the crankcase 2 Install Main axle assembly 1 NOTE Stake the main axle assembly bearing housing bolts 2 at a cutout a in the main axle assem bly bearing housing 3 3 Install Shift fork C 1 Shift drum assembly 2 Shift fork guide bar 3 NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following s...

Page 282: ...roove 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 inserted into the grooves d in the upper crankcase T R Shift drum retainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 1 2 d 4 5 b a 3 3 c c ...

Page 283: ... 6 3 INSTALLING THE RADIATOR 6 3 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 6 8 WATER PUMP 6 9 CHECKING THE WATER PUMP 6 10 INSTALLING THE WATER PUMP 6 10 ...

Page 284: ...reservoir hose 1 3 Coolant reservoir 1 4 Radiator fan motor coupler 2 Disconnect 5 Radiator cap 1 6 Radiator 1 7 Radiator fan 2 8 Radiator inlet hose 1 9 Radiator inlet pipe 1 10 Radiator outlet hose holder 1 11 Radiator outlet hose 1 12 Radiator outlet pipe 1 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft...

Page 285: ...e dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 4 7 7 4 9 12 10 11 6 8 1 3 2 5 13 3 3 ...

Page 286: ...nd make sure there is no drop in pressure 4 Check 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 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure B...

Page 287: ...NGING THE COOLANT on page 3 19 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Oil cooler outlet hose 1 2 Oil cooler inlet hose 1 3 Water jacket joint 1 4 O ring 1 5 Water jacket joint inlet hose 1 6 Water pump outlet pipe 1 7 Oil cooler union bolt 1 8 Gasket 1 9 Oil cooler 1 T R 63 Nm 6 3 m kg 45 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New New LS LS 4 3 5 6 2 7 9 10 8 1 E New ...

Page 288: ...O ring 1 For installation reverse the removal proce dure Removing the oil cooler Order Job Parts to remove Q ty Remarks T R 63 Nm 6 3 m kg 45 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New New LS LS 4 3 5 6 2 7 9 10 8 1 E New ...

Page 289: ...lling the oil cooler lubricate the its union bolt 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 19 Crankcase with the specified amount of the recom mended engine oil Re...

Page 290: ...ASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Coolant temperature sensor coupler 1 Disconnect 2 Thermostat outlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib 3 4 2 1 ...

Page 291: ...lace it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or r...

Page 292: ... 4 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Clutch cable 1 Disconnect 2 Water pump inlet hose 1 3 Water pump outlet hose 1 4 Water pump breather hose 1 5 Water pump assembly 1 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib New LS L...

Page 293: ...2 NOTE Align the slit a on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified p...

Page 294: ...E SECONDARY INJECTORS 7 7 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 7 7 THROTTLE BODIES 7 8 CHECKING THE PRIMARY INJECTORS 7 12 CHECKING THE THROTTLE BODIES 7 12 CHECKING THE ROLLOVER VALVE for California only 7 12 CHECKING THE FUEL PRESSURE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 7 13 ADJUSTING THE THROTTLE POSITION SENSOR FOR THRO...

Page 295: ...1 Disconnect 5 Fuel tank overflow hose 1 Disconnect 6 Fuel tank breather hose 1 Except for California Disconnect 7 Fuel tank 1 8 Fuel tank upper cover 1 9 Fuel tank overflow hose fuel tank to hose joint 1 10 Fuel tank breather hose fuel tank to hose joint 1 Except for California 11 Fuel tank breather hose fuel tank to rollover valve 1 For California only 12 Fuel pump 1 11 4 6 12 6 3 5 2 9 1 8 10 7...

Page 296: ...verse the removal proce dure Removing the fuel tank and fuel pump Order Job Parts to remove Q ty Remarks 11 4 6 12 6 3 5 2 9 1 8 10 7 13 1 New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 297: ...illus tration Make sure that the fuel pipe does not contact the ground otherwise the fuel pump could be damaged EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly...

Page 298: ...1017 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 NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the ...

Page 299: ...el rail 1 Disconnect 6 Upper air filter case 1 7 Secondary injector holder 1 8 Cylinder 1 secondary injector coupler 1 Disconnect 9 Cylinder 2 secondary injector coupler 1 Disconnect 10 Cylinder 3 secondary injector coupler 1 Disconnect 11 Cylinder 4 secondary injector coupler 1 Disconnect 12 Sub wire harness 3 1 13 Secondary injector fuel rail 1 14 Secondary injector 4 6 16 19 19 17 5 4 18 3 1 15...

Page 300: ...r case joint lower 2 For installation reverse the removal proce dure Removing the air filter case and secondary injectors Order Job Parts to remove Q ty Remarks 6 16 19 19 17 5 4 18 3 1 15 5 3 3 9 4 7 9 8 12 10 11 13 14 14 14 14 2 New New New New New T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LT T R 2 Nm 0 2 m kg 1 4 ft Ib T R 1 5 Nm 0 15 m kg 1 08 ft lb ...

Page 301: ...sing any tools Before removing the hose place a few rags in the area under where it will be removed ET2C01017 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Damage Replace ET2C01006 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 1 Connect Fuel hose primary injector fuel rail to second ary injector fuel rail CAUTION EC2C01017 When installing the fuel hose ma...

Page 302: ...R CASE on page 7 5 1 Canister purge hose throttle body 4 to 3 way joint 1 2 Canister purge hose throttle body 2 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 1 7 6 5 4 8 2 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7...

Page 303: ...onnect 2 Throttle position sensor for throttle cable pulley coupler 1 Disconnect 3 Throttle position sensor for throttle valves cou pler 1 Disconnect 4 Sub wire harness 2 coupler 1 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Fuel hose primary injector fuel rail to second ary injector fuel rail 1 7 Fuel hose fuel tank to primary injector fuel rail 1 8 Throttle cable decelerator c...

Page 304: ...Heat protector 1 13 Throttle body joint 4 For installation reverse the removal proce dure Removing the throttle body assembly Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib 7 10 3 2 1 5 8 8 11 4 12 6 9 13 ...

Page 305: ...harness 2 1 7 Intake air pressure sensor hose 7 8 Intake air pressure sensor 1 9 Primary injector fuel rail 1 10 Primary injector 4 11 Throttle position sensor for throttle valves 1 12 Throttle position sensor for throttle cable pulley 1 13 Throttle bodies 1 CAUTION ECA14600 The throttle bodies should not be disas sembled For installation reverse the removal proce dure New New New 5 10 8 7 7 7 6 1...

Page 306: ...ation The rollover valve must be in an upright posi tion when checking the airflow EAS27010 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat Refer to GENERAL CHASSIS on page 4 1 b Disconnect the fuel hose fuel tank to primary injector fuel rail 1 from the primary injector fuel rail WARNING EW2C01008 Cover fuel hose connections with a cloth when disconnecting them Residual p...

Page 307: ...ENSOR FOR THROTTLE CABLE PULLEY 1 Check Throttle position sensor for throttle cable pul ley Refer to CHECKING THE THROTTLE PO SITION SENSOR FOR THROTTLE CABLE PULLEY on page 8 98 2 Adjust Throttle position sensor angle a Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circuit tester to the throttle position sensor c Measure the throttle position s...

Page 308: ...hrottle body joints 1 NOTE Be sure to install the throttle body joints with the L mark onto the throttle body openings for cyl inders 1 and 2 and the joints with the R mark onto the openings for cylinders 3 and 4 T R Throttle body joint bolt 10 Nm 1 0 m kg 7 2 ft lb 3 3 1 2 L R 1 ...

Page 309: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM 2 1 2 4 3 4 3 6 4 5 A A ...

Page 310: ...M 7 16 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 cylinder head cover 5 Reed valve assembly 6 Exhaust port ...

Page 311: ...n page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 1 Air induction system cover 1 2 Air induction system solenoid coupler 1 Disconnect 3 Air induction system hose air filter case to air cut off valve 1 4 Air induction system hose air cut off valve to cylinder head cover 2 5 Air cut off valve 1 For installation reverse the removal proce dure 1 4 4 5 3 2 ...

Page 312: ...alves 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 1 3 LT LT LT LT 1 2 2 3 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 313: ...s to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe assembly until the temperature be comes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Che...

Page 314: ...RAM 8 13 TROUBLESHOOTING 8 15 LIGHTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 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 SELF DIAGNOSTIC FUNCTION TABLE 8 36 TROUBLESHOOTING METHOD 8 39 DIAGNOSTIC MODE 8 40 TROUBLESHOOTIN...

Page 315: ...8 94 CHECKING THE RECTIFIER REGULATOR 8 94 CHECKING THE HORN 8 95 CHECKING THE OIL LEVEL SWITCH 8 95 CHECKING THE FUEL SENDER 8 95 CHECKING THE SPEED SENSOR 8 96 CHECKING THE RADIATOR FAN MOTORS 8 96 CHECKING THE COOLANT TEMPERATURE SENSOR 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 8 98 CHECKING THE FUEL PUMP ...

Page 316: ...W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 R W G Y L W2 R W R ...

Page 317: ...ground 13 Relay unit 16 Neutral switch 17 Sidestand switch 22 ECU engine control unit 23 Spark plug 24 Cylinder 1 ignition coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 40 Crankshaft position sensor 47 Lean angle sensor 64 Engine stop switch ...

Page 318: ...om 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 sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open 1 4 5 10 12 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Mai...

Page 319: ...KING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 92 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 92 Replace th...

Page 320: ...eck the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 91 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 93 Replace the lean angle sensor 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 P...

Page 321: ... Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK Dg Y Br WR Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLACK BROWN R W R G Br L Br L L Y L B2 RED L Y L B2 RED L Y L B R W G Y L W2 R W R B B Br W W W Br L Br L Br R Y R Y R Y R W B G B G B Y G Y2 Y B2 Y B2 Br G Br G Br G R Y R Y B L B L L L R L L W2 R ...

Page 322: ... switch 4 Ignition fuse 6 Main fuse 7 Battery 8 Starter relay 10 Starter motor 11 Engine ground 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 64 Engine stop switch 65 Start switch 70 Clutch switch ...

Page 323: ...osed 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 condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions ...

Page 324: ... THE CLUTCH LEVER 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 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 Engine ground ...

Page 325: ... battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 93 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 35 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off...

Page 326: ...SWITCHES on page 8 81 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 14 Check the entire starting system s wiring R...

Page 327: ...R R R R W L W B Br Br R R R R R B W W W W W W R R R R R B B B B A R W L W2 R B G Y L W BLACK R W L W3 R W BLUE BLUE R W R G Br L Br L L Y L B2 R W G Y L W2 R W R B B Br W W W Br L Br L Br R Y R Y R Y W W W B R W W W 63 62 64 65 13 12 6 2 5 4 3 1 8 9 7 10 11 85 86 RED L Y L B2 RED L Y L B R Br L R Br L ...

Page 328: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 6 Main fuse 7 Battery 11 Engine ground ...

Page 329: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 94 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 94 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT...

Page 330: ...B Lg P B R L L L G Lg R W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y ...

Page 331: ...eam indicator light 60 Meter light 68 Dimmer switch 75 Front right turn signal position light 76 Front left turn signal position light 77 Headlight low beam 78 Headlight high beam 79 Auxiliary light 80 License plate light 82 Tail brake light 83 Headlight relay on off 84 Headlight relay dimmer 86 Headlight fuse ...

Page 332: ...place the bulb s and bulb socket s 2 Check the fuses Main and headlight Refer to CHECKING THE FUS ES on page 8 85 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 5 Check the dimmer switch Refer to CHEC...

Page 333: ...LIGHTING SYSTEM 8 20 NG OK 8 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting sys tem s wiring This circuit is OK ...

Page 334: ... W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 R W G Y L W2 R W R B B B...

Page 335: ...Neutral indicator light 52 Tachometer 53 Shift timing indicator light 54 Multi function meter 56 Coolant temperature warning light 58 Left turn signal indicator light 59 Right turn signal indicator light 61 Oil level switch 63 Front brake light switch 66 Turn signal relay 69 Horn switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn...

Page 336: ... 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Check the...

Page 337: ...ck the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 81 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 signaling system s wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 84 Replace the turn signal ...

Page 338: ...utral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 91 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 signaling system s wiring This circuit is OK 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 95 Replace the oil level switch 2 Check the en...

Page 339: ... 8 97 Replace the coolant temperature sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 96 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connec...

Page 340: ...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 signaling system s wiring This circuit is OK ...

Page 341: ...W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 R W G Y L W2 R W R ...

Page 342: ...use 6 Main fuse 7 Battery 11 Engine ground 22 ECU engine control unit 42 Coolant temperature sensor 87 Radiator fan motor relay 88 Right radiator fan motor fuse 89 Left radiator fan motor fuse 90 Right radiator fan motor 91 Left radiator fan motor ...

Page 343: ...e battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 96 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 89 Replace the radiator fan motor relay 6 Check the coolant temperature Refer to CHECKING THE COOL A...

Page 344: ...G Lg R W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 R W G Y L W2...

Page 345: ... ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 28 Primary injector 1 29 Primary injector 2 30 Primary injector 3 31 Primary injector 4 32 Secondary injector 1 33 Secondary injector 2 34 Secondary injector 3 35 Secondary injector 4 36 Throttle servo motor 37 Air induction system solenoid 38 EXUP servo motor 39 O2 sensor 40 Crankshaft position sensor 41 Air temperature sensor...

Page 346: ...fuel reserve tripmeter 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 fuel injection 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 f...

Page 347: ...ymptom Able un able to start Able un able to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driv en Unable Able 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Int...

Page 348: ...from the O2 sensor Able Able 30 Lean angle sensor Latch up detected No normal signal is received from the lean angle sensor Unable Unable 33 Cylinder 1 ignition coil open circuit Primary lead of the cylinder 1 ig nition coil open circuit detected Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 34 Cylinder 2 ignition coil open circuit Primary lead...

Page 349: ...OM An error is detected while reading or writing on EEPROM CO ad justment value Able Able 46 Vehicle system power supply monitoring voltage Power supply is not normal Able Able 50 ECU internal malfunc tion ECU memory is faulty When this malfunction is detected in the ECU the fault code number might not appear on the meter Able Un able Able Un able 59 Throttle position sen sor for throttle cable pu...

Page 350: ...agnostic mode Refer to Sensor operation table and Actuator oper ation 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 Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unable Unabl...

Page 351: ... the clock LCD 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET buttons NOTE To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT but...

Page 352: ...ection is loose Open or short circuit in wire harness Defective throttle position sensor for throt tle valves Malfunction in ECU Improperly installed throttle position sensor for throttle valves 01 13 17 EXUP servo motor circuit open or short circuit detect ed or loose connection Open or short circuit in wire harness Defective EXUP servo motor potentiome ter circuit 53 18 EXUP servo motor is stuck...

Page 353: ...cuit in wire harness Malfunction in ignition coil Malfunction in ECU 31 35 Open circuit detected in the primary lead of the cylin der 3 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 32 36 Open circuit detected in the primary lead of the cylin der 4 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU 33 39 Open circ...

Page 354: ...Defective throttle position sensor Improperly installed throttle position sensor Malfunction in ECU 14 15 60 Throttle servo motor open or short circuit detect ed Defective throttle servo mo tor Malfunction in ECU servo motor driving system Open or short circuit in wire harness Defective throttle servo motor potentiome ter circuit Stuck throttle servo motor mechanism Stuck throttle servo motor moto...

Page 355: ...ally mea sured air temperature with the meter display value 06 Coolant temperature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the meter display val ue 07 Vehicle speed pulse 0 999 Check that the number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Remove the l...

Page 356: ...ransmis sion in gear Stand retracted ON Stand extended OFF 21 Neutral switch Shift the transmission Neutral ON In gear OFF 60 EEPROM fault cylinder No No history 00 History exists 01 04 fault cylinder No If more than one cylinder is defective the display changes every two seconds to show all the detected cyl inder numbers When all cylinder numbers are shown the display re peats 61 Malfunction hist...

Page 357: ...ode numbers are shown the display re peats To reinstate set the engine stop switch from to 70 Control number 00 Diag nostic code No Item Meter display Checking method Diag nostic code No Item Actuation Checking method 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect...

Page 358: ... Actuates the primary injector 4 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 4 five times 40 Secondary injector 1 Actuates the secondary in jector 1 five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the secondary injector 1 five times 41 Secondary injec...

Page 359: ...tion system solenoid five times 50 Fuel injection system relay Actuates the fuel injection system relay five times at one second intervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel injection system relay five times 51 Radiator fan m...

Page 360: ... 2 Connections Cylinder identification sensor cou pler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the cylinder identifica tion sensor coupler...

Page 361: ...Crankshaft position sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gr...

Page 362: ...is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler black blue black blue pink white pink white blue blue 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 100 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detache...

Page 363: ...ng the main switch to ON 2 Connections Throttle position sensor for throttle valves coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between thrott...

Page 364: ...vo motor potenti ometer circuit Execute the diagnostic mode Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check t...

Page 365: ...tch coupler blue black blue black Between main switch coupler and relay unit coupler blue yellow blue yellow Between relay unit coupler and sidestand switch coupler blue black blue black Between sidestand switch cou pler and engine ground black black 3 Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 8 81 Fault code No 20 Symptom When the main switch is turned...

Page 366: ...nsor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 97 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Air temperature sensor coupler Main wire harness...

Page 367: ...be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Reinstated au tomatically if a normal signal is received 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between atmospheric pressure sensor coupler and ECU cou pler black blue black blue pink pink b...

Page 368: ...etween O2 sensor coupler and ECU coupler gray green gray green black blue black blue pink black pink black red blue red blue 4 Check fuel pressure Refer to THROTTLE BODIES on page 7 8 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom Latch up detected No normal signal is received from the lean angle sensor Diagnostic code No 08 Lean angle sensor Order Item components and probable...

Page 369: ...imary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 92 Fault code No 34 Symptom Open circuit detected in the primary lead of the cylinder 2 ignition coil Diagnostic code No 31 Cylinder 2 ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 2 ignition coil coupler Main wi...

Page 370: ...lled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the cylinder 3 ig nition coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler red black red blue orange green ...

Page 371: ... Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the cylinder 4 ig nition coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU cou pler main wire harness red black red blue gr...

Page 372: ...y be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Cranking the engine Connect the fuel injector couplers 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between primary injector cou pler and ECU coupler red blue red blue 1 red black red black 2 gr...

Page 373: ...led out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Execute the di agnostic mode Code No 63 Set the engine stop switch to 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between secondary injector coupler and ECU coupler red blue red blue 1 white blue white...

Page 374: ...that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Reinstated au tomatically if a normal signal is received 2 Open or short circuit in lead Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective...

Page 375: ... the speed sensor by operating the vehicle A 2 Connections Speed sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely A 3 Open or short circuit in lead Repair or replace if there is an open or short circuit Between speed sensor coupler and...

Page 376: ... coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely B 3 Open circuit in neutral switch lead Repair or replace if there is an open circuit Between neutral switch coupler and relay unit coupler sky blue sky blue Between ECU coupler and main switch coupler blue black blue blac...

Page 377: ...f there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON when the engine stop switch is set to 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler blue yellow blue yellow red blue red blue Between relay unit coupler and starter relay coupler red red Between relay unit cou...

Page 378: ...N Readjust the exhaust gas volume after it is reinstated Fault code No 46 Symptom Power supply is not normal Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 13 Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness R...

Page 379: ...d in the specified position Turning the main switch to ON 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is ...

Page 380: ...t in wire harness Repair or replace if there is an open or short circuit Between throttle servo motor coupler and ECU coupler yellow red yellow red light green red light green red 4 Defective throttle servo motor Execute the diagnostic mode Code Nos 01 13 Replace the throttle body as sembly if defective 5 Malfunction in ECU Replace the ECU Fault code No Er 1 Symptom No signals are received from th...

Page 381: ...pler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the ...

Page 382: ...r assembly coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue 3 Malfunction i...

Page 383: ...R W L W W W W R W R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br W R Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 R W G Y L W2 R W ...

Page 384: ...UMP SYSTEM 8 74 3 Main switch 4 Ignition fuse 6 Main fuse 7 Battery 9 Fuel injection system fuse 11 Engine ground 13 Relay unit 15 Fuel pump relay 18 Fuel pump 22 ECU engine control unit 64 Engine stop switch ...

Page 385: ...6 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 89 Replace the relay unit 6 Check the fuel pump Refer to...

Page 386: ...ELECTRICAL COMPONENTS 8 77 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 387: ...in fuse 7 Fuel injection system fuse 8 Starter relay 9 Neutral switch 10 EXUP servo motor 11 Rear brake light switch 12 O2 sensor 13 Sidestand switch 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Fuse box radiator fan motor signaling system ignition headlight ...

Page 388: ...ELECTRICAL COMPONENTS 8 79 1 5 4 3 2 6 7 8 9 10 12 13 11 14 15 16 17 ...

Page 389: ...6 Lean angle sensor 7 Relay unit 8 Turn signal relay 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 13 Throttle position sensor for throttle valves 14 Cylinder identification sensor 15 Radiator fan motor relay 16 Headlight relay dimmer 17 Headlight relay on off ...

Page 390: ...1 EAS27980 CHECKING THE SWITCHES Dg Y Br W R Y Ch L Y B B Y Br B B BLUE G Y L W R W R B B Br BLUE B B BROWN Br G Y 7 8 9 10 11 2 3 4 1 5 6 Sb R Y R B L W B ON OFF R Br L L Y L B Y R Y Br B L Y2 B Y Ch Dg Br W RED L Y L B R Br L ...

Page 391: ...NENTS 8 82 1 Clutch switch 2 Main switch 3 Dimmer switch 4 Horn switch 5 Turn signal switch 6 Sidestand switch 7 Front brake light switch 8 Engine stop switch 9 Start switch 10 Neutral switch 11 Rear brake light switch ...

Page 392: ... 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a g...

Page 393: ...e condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW2C01001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC2C01002 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touc...

Page 394: ...ASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows agai...

Page 395: ... the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged accord ing to the instructions for the charging method If the battery is overcharged the electrolyte level will drop considerab...

Page 396: ...harger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery 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 dis connect the battery charger and let the bat tery cool before reconnecting it...

Page 397: ...minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging NOTE 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 bat tery NOTE If the current is lower than the standard chargi...

Page 398: ...circuit cut off relay Relay unit fuel pump relay Headlight relay on off 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 R B R R R W R 2 1 4 3 W L 1 Positive battery terminal 2 Negative battery terminal 3 Positive...

Page 399: ...Replace a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative te...

Page 400: ...03112 Analog pocket tester YU 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe s...

Page 401: ...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 b Turn the main switch to ON and engine stop switch to c Measure the ignition spark gap a Primary coil resistance 1 19 1 61 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red black 1 Negative tester probe orange o...

Page 402: ...ensor coupler as shown c Turn the main switch to ON d Turn the lean angle sensor to 65 e Measure the lean angle sensor output volt age ET2C01012 CHECKING THE STARTER MOTOR OPERATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 11 a Connect the positive battery terminal 1 and starter mot...

Page 403: ...place the rectifi er regulator a Set the engine tachometer to the cylinder 1 ignition coil b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage Stator coil resistance 0 12 0 18 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1...

Page 404: ...ecification Replace the oil level switch a Connect the pocket tester Ω 100 to the oil level switch terminal as shown b Measure the oil level switch resistance EAS28230 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Coil resistance 1 15 1 25 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe horn terminal 1 Negative tester probe horn terminal 2 1...

Page 405: ...full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTORS 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement Fuel sender resistance 900 1050 Ω at 25 C 77 F Pock...

Page 406: ...at the coolant then let it cool down to the specified temperature e Measure the coolant temperature sensor re sistance EAS28300 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Remove Throttle position sensor for throttle valves from the throttle body 2 Check Throttle position sensor for throttle valves maximum resistance Out of specification Replace the throttle position sensor for thr...

Page 407: ...OSI TION SENSOR FOR THROTTLE CABLE PUL LEY on page 7 13 EAS28350 CHECKING THE FUEL PUMP WARNING EWA13850 Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally...

Page 408: ...RIC PRESSURE SENSOR 1 Check Atmospheric pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the at mospheric pressure sensor coupler as shown b Turn the main switch to ON c Measure the atmospheric pressure sensor output voltage Solenoid resistance 18 22 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brow...

Page 409: ... the main switch to ON c Measure the intake air pressure sensor out put voltage ET2C01022 CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor WARNING EW2C01002 Handle the air temperature sensor with special care Never subject the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check Air temperature sensor resistance Out of specificatio...

Page 410: ...sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do not 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 air temperature sensor resis tance Pocket tester 90890 03112 Analog pocket tester YU 03112 C 3 1 2 ...

Page 411: ...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 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 412: ...ed fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4...

Page 413: ...ve 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 returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Cl...

Page 414: ...ake 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 EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly Cra...

Page 415: ... light does not come on Wrong tail brake light LED Too many electrical accessories Incorrect connection Burnt out tail brake light LED Tail brake light bulb burnt out Wrong tail brake light LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incor...

Page 416: ...R B L B L R L B L B L G L L BLACK BLACK Dg Y Br W R Y Ch L Y B B Y Br BLUE DARK GREEN BLUE L Y R B L W R W L W3 L W2 R W Sb W L Y2 Br W Br Dg B BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK Dg Y Br WR Y Ch L Y2 B B Y Br BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE DARK BLUE BLACK BROWN R W R G Br L Br L L Y L B2 RED L Y L B2 RED L Y L B R W G Y L W...

Page 417: ... A A A A B B BLACK BLACK BLACK DARK BLUE B GRAY GRAY GRAY GRAY GRAY GRAY GRAY GRAY GRAY BLUE DARK GREEN BLUE GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK DARK GREEN BLACK BLACK BROWN BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLACK BROWN RED RED 24 25 26 27 23 22 23 23 23 36 37 38 35 34 33 32 31 30 29 28 46 42 41 39 40 43 20 21 44 45 60 6...

Page 418: ...al indicator light 59 Right turn signal indicator light 60 Meter light 61 Oil level switch 62 Right handlebar switch 63 Front brake light switch 64 Engine stop switch 65 Start switch 66 Turn signal relay 67 Left handlebar switch 68 Dimmer switch 69 Horn switch 70 Clutch switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn signal po...

Page 419: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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