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ENG

EAS00393

REMOVING THE CONNECTING RODS AND
PISTONS

The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

• connecting rod cap

1

• big end bearings

NOTE:

@

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

2. Remove:

• piston pin clips

1

• piston pin

2

• piston

3

• connecting rod

4

CAUTION:

@

Do not use a hammer to drive the piston
pin out.

NOTE:

@

• For reference during installation, put identifi-

cation marks on the piston crown.

• Before removing the piston pin, deburr the

piston pin clip’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

5

.

Piston pin puller

YU-01304

CONNECTING RODS AND PISTONS

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Содержание FJR1300R

Страница 1: ...LIT 11616 16 18 5JW 28197 10 FJR1300R FJR1300RC SERVICE MANUAL...

Страница 2: ...002 by Yamaha Motor Corporation U S A First edition June 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly pro...

Страница 3: ...nformation changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamah...

Страница 4: ...f each page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and c...

Страница 5: ...fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication p...

Страница 6: ......

Страница 7: ...GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TR...

Страница 8: ...TS 1 31 IMPORTANT INFORMATION 1 35 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 35 REPLACEMENT PARTS 1 35 GASKETS OIL SEALS AND O RINGS 1 35 LOCK WASHERS PLATES AND COTTER PINS 1 36 BEARINGS AND OIL SEAL...

Страница 9: ...EM DIAGRAMS 2 38 CABLE ROUTING 2 42 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART...

Страница 10: ...EM 3 47 CHANGING THE COOLANT 3 48 CHASSIS 3 51 ADJUSTING THE FRONT BRAKE 3 51 ADJUSTING THE REAR BRAKE 3 52 CHECKING THE BRAKE FLUID LEVEL 3 53 CHECKING THE BRAKE PADS 3 54 ADJUSTING THE REAR BRAKE LI...

Страница 11: ...RAKE MASTER CYLINDER 4 26 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 27 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 30 FRONT BR...

Страница 12: ...CK ABSORBER ASSEMBLY 4 86 CHECKING THE CONNECTING ARM AND RELAY ARM 4 86 INSTALLING THE RELAY ARM 4 87 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 87 SWINGARM 4 88 REMOVING THE SWINGARM 4 90 CHECKIN...

Страница 13: ...HEAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5...

Страница 14: ...ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PUMP 5 63 INSTALLING THE OIL STRAINER 5 63 INSTALLING THE OIL PAN 5 63 MIDDLE GEAR 5 65 REMOVING THE MIDDLE GEAR 5 69 DISASSEMBLING THE MIDDLE DRIVE SH...

Страница 15: ...DRUM ASSEMBLY 5 115 CHECKING THE TRANSMISSION 5 115 INSTALLING THE TRANSMISSION 5 117 BALANCERS 5 118 FRONT BALANCER 5 118 REAR BALANCER 5 119 CHECKING THE BALANCER 5 120 INSTALLING THE FRONT BALANCER...

Страница 16: ...7 38 AIR INDUCTION SYSTEM 7 40 AIR INJECTION 7 40 AIR CUT OFF VALVE 7 40 AIR INDUCTION SYSTEM DIAGRAMS 7 41 AIR CUT OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 7 42 REED VALVES 7 43 CHECKING THE...

Страница 17: ...8 30 CHECKING THE LIGHTING SYSTEM 8 32 SIGNALING SYSTEM 8 36 CIRCUIT DIAGRAM 8 36 TROUBLESHOOTING 8 38 CHECKING THE SIGNALING SYSTEM 8 39 COOLING SYSTEM 8 46 CIRCUIT DIAGRAM 8 46 TROUBLESHOOTING 8 47...

Страница 18: ...ATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 6...

Страница 19: ...YCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL CODE The model code label 1 is af...

Страница 20: ...in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This sys...

Страница 21: ...the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake tempera...

Страница 22: ...tmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throt...

Страница 23: ...sensor Then the signals are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection...

Страница 24: ...switch is tripped 2 Operating the headlight illumination relay On the model for Europe the ECU causes the headlight relay 2 to output a constant ON signal provided that the main switch is ON On the m...

Страница 25: ...nstream of the pump The pump consists of a pump unit electric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to preve...

Страница 26: ...n intake vacuum is applied to the spring chamber via a pipe When the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the dia phragm ope...

Страница 27: ...that is integrated with the needle to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the...

Страница 28: ...sition of the crankshaft and the speed of the engine The ignition timing is then determined in accordance with the calcu lated data in order to determine the corresponding injection timing Based on th...

Страница 29: ...s a signal and sends it to the ECU Based on this signal and the signal from the crankshaft position sensor the ECU then actuates the injector of the cylinder that is currently in order to supply fuel...

Страница 30: ...oves in unison with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position...

Страница 31: ...silicon diaphragm converts the intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate elec...

Страница 32: ...sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atm...

Страница 33: ...tration level is known When a difference in the oxygen concentration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and gen...

Страница 34: ...ilt of the float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the motorcycle has overturned and stops the del...

Страница 35: ...l it sends an injection command to the injectors Furthermore the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on...

Страница 36: ...s This system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating conditio...

Страница 37: ...he injector The battery voltage determines the reactive injection duration High voltage short reactive injection duration Low voltage long reactive injection duration LIST OF FUEL INJECTION COMPENSATI...

Страница 38: ...n obtained through the throttle position intake air pressure and engine speed to which injection duration compensation based on the sig nals from various sensors such as the intake temperature sensor...

Страница 39: ...ct fuel only once immediately upon receiving the signals from the sensors during the cranking of the engine This is called asyn chronous injection in contrast to synchronous injection which is a norma...

Страница 40: ...he coolant tem perature determines the initial starting enrichment coefficient the coefficient subsequently changes in accordance with the damping factor The enrichment ratio is the highest immediatel...

Страница 41: ...coolant temperature The coefficient increases with the decrease in the coolant temperature and decreases with the increase in the coolant temperature The ratio of fuel enrichment also changes with th...

Страница 42: ...creases the actual enrich ment volume The enrichment volume is executed in accordance with the acceleration enrichment coefficient when the movement of the throttle position sensor has met the acceler...

Страница 43: ...all the cylinders is stopped when fuel cut off control is executed thus improving fuel economy Engine speed Duration Fuel cut off control stopping fuel injection Basic injection duration Basic inject...

Страница 44: ...st gas is provided in the exhaust pipe for the purpose of maximizing the performance of the three way cat alytic converter and to clean the exhaust gas at a high degree of efficiency Based on this dat...

Страница 45: ...on of platinum and are converted into harmless carbon dioxide CO2 and water H2O resulting in cleaner exhaust gases The NOx is reduced by the reduction function of rhodium which converts NOx into harml...

Страница 46: ...mixture is lean as indicated by excessive O2 region B Under these conflicting characteristics the system maintains the mixture within an extremely narrow range C of stoichiometric ratio 14 7 1 As a r...

Страница 47: ...e basic injection volume based on the signals that are input from various sensors and regulates the duration of the current applied to the injectors Current is applied to the injectors enabling them t...

Страница 48: ...through the reed valve The air cut off valve is controlled by the signals from the ECU in accordance with the combustion conditions Ordinarily the air cut off valve opens to allow the air to flow dur...

Страница 49: ...air passage and flows into the reed valves of the cyl inders When the current flows to the solenoid coil in accordance with a signal from the ECU the plunger in the core becomes attracted towards the...

Страница 50: ...howing the time after the error has been corrected 1 Fuel meter 2 Clock 3 Coolant temperature meter 4 TRIP meter 5 TRIP ODO meter 6 RESET button 7 SELECT button 8 Engine trouble warn ing light 9 Oil l...

Страница 51: ...ts a sys tem check System normal Normal meter display Malfunction detection A fault code number appears on the clock LCD The engine trouble warning light illuminates The engine cannot be started in th...

Страница 52: ...URES 1 Clock 2 TRIP meter 3 RESET button 4 SELECT button 5 Engine trouble warning light 140 150 160 170 180 130 120 220 240 260 280 200 180 160 140 MPH Km h F L H E SELECT RESET TRIP TRIP km mile km m...

Страница 53: ...d place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PA...

Страница 54: ...oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION Do not spin the bearing with compressed a...

Страница 55: ...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 Ch...

Страница 56: ...s are needed to remove the main axle assembly YM 01229 Gear holder This tool is needed when removing or installing the coupling gear nut YM 01230 Final drive gear lash tool This tool is needed when me...

Страница 57: ...s tool is needed to hold the damper rod assembly when loosen or tighten the damper rod assembly bolt YM 01471 Frame spanner socket This tool is needed to loosen or tighten the spacer bolt YS 01880 A P...

Страница 58: ...e gauge Oil pressure adaptor B These tools are needed to measure engine oil pressure Valve spring compres sor set YM 04019 Valve spring compres sor attachment YM 04108 Valve spring compressor set Valv...

Страница 59: ...eeded when removing or installing the damper spring YM 04097 Valve guide remover 5 This tool is needed to remove and install the valve guide YM 04098 Valve guide installer 5 This tool is needed to ins...

Страница 60: ...001 05 01 Quick Gasket This sealant is used to seal two mating surfaces e g crankcase mating sur faces YM 04140 Bearing retainer wrench This tool is needed when removing or installing the middle drive...

Страница 61: ...m 55 9 in Seat height 805 mm 31 7 in Wheelbase 1 515 mm 59 6 in Minimum ground clearance 135 mm 5 3 in Minimum turning radius 3 100 mm 122 0 in Weight Wet with oil and a full fuel tank 274 kg 604 lb U...

Страница 62: ...reserve 25 L 22 01 Imp qt 26 43 US qt Reserve only 5 L 4 40 Imp qt 5 29 US qt Engine oil Lubrication system Wet sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 5 C 40 F or higher...

Страница 63: ...7 kPa 0 93 1 23 kg cm2 13 27 17 45 psi Valve relief pressure 4 9 kPa 0 05 kg cm2 0 70 psi Radiator core Width 360 mm 14 17 in Height 295 8 mm 11 65 in Depth 27 mm 1 06 in Coolant reservoir Capacity 0...

Страница 64: ...ance 0 028 0 062 mm 0 0011 0 0024 in Intake camshaft lobe dimensions Measurement A 33 05 33 15 mm 1 3012 1 3051 in 32 05 mm 1 2618 in Measurement B 24 997 25 097 mm 0 9841 0 9881 in 23 997 mm 0 9448 i...

Страница 65: ...0433 in 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve margin thickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake...

Страница 66: ...39 7 mm 1 56 in 37 7 mm 1 48 in Exhaust 39 7 mm 1 56 in 37 7 mm 1 48 in Installed length valve closed Intake 33 mm 1 30 in Exhaust 33 mm 1 30 in Compressed spring force installed Intake 136 158 N 13 9...

Страница 67: ...094 in Height H 5 mm 0 2 in Piston pin bore in the piston Diameter 19 004 19 015 mm 0 7482 0 7486 in 19 045 mm 0 7498 in Offset 0 5 mm 0 0197 in Offset direction Intake side Piston pins Outside diamet...

Страница 68: ...2 0 0019 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink Small end inside diameter 19 005 19 018 mm 0 7482 0 7487 in Crankshaft Width A 61 6 63 2 mm 2 425 2 488 in Width B 325 1 3...

Страница 69: ...length 6 44 mm 0 2535 in Push rod bending limit 0 2 mm 0 0079 in Transmission Transmission type Constant mesh 5 speed Primary reduction system Helical gear Primary reduction ratio 75 48 1 563 Seconda...

Страница 70: ...2 94 kgf cm2 41 81 psi Throttle bodies Model manufacturer quantity 42EHS MIKUNI 4 Intake vacuum pressure 33 3 kPa 250 mm Hg 9 8 in Hg Throttle cable free play at the flange of the throttle grip 3 5 mm...

Страница 71: ...0 5 mm 0 02 in Rear wheel Wheel type Cast wheel Rim Size 17 M C MT 5 50 Material Aluminum Wheel travel 125 mm 4 92 in Wheel runout Max radial wheel runout 1 0 mm 0 04 in Max lateral wheel runout 0 5 m...

Страница 72: ...ameter thickness 298 5 mm 11 73 0 20 in Min thickness 4 5 mm 0 18 in Max deflection 0 1 mm 0 004 in Brake pad lining thickness 5 5 mm 0 22 in 0 5 mm 0 02 in Master cylinder inside diameter 14 mm 0 55...

Страница 73: ...0 999 kg mm 55 96 lb in Spring stroke K2 91 135 mm 3 58 5 31 in Optional spring available No Fork oil Recommended oil Suspension oil M1 Quantity each front fork leg 670 cm3 23 6 Imp oz 22 3 US oz Leve...

Страница 74: ...2 91 in 72 52 mm 2 86 in Installed length 65 4 mm 2 57 in Spring rate K1 71 6 N mm 7 30 kg mm 408 86 lb in Spring stroke K1 0 31 3 mm 0 1 23 in Spring rate K2 102 N mm 10 4 kg mm 582 45 lb in Spring s...

Страница 75: ...system System type AC magneto Model manufacturer TLNZ79 DENSO Nominal output 14 V 490 W at 5 000 r min Stator coil resistance color 0 15 0 23 W W Voltage regulator Regulator type Semiconductor short...

Страница 76: ...0 96 in 23 5 mm 0 93 in Mica undercut 1 5 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 A Coil resistance 4 18 4 62 Horn Horn type Plane Model manufacturer quantity YF 12...

Страница 77: ...85 0 F Valve lift full open 8 mm 0 31 in Intake air temperature sensor Model manufacturer 25978 MITSUBISHI Resistance 5 4 6 6 at 80 C 176 F Coolant temperature sender Model manufacturer 8CC MITSUBISHI...

Страница 78: ...specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0...

Страница 79: ...2 LT Stator assembly lead holder Screw M6 1 6 0 6 4 3 Pickup coil rotor cover Bolt M6 8 12 1 2 8 7 Ignition timing check bolt M8 1 15 1 5 11 Crankshaft position sensor Bolt M5 2 4 0 4 2 9 LT Pickup c...

Страница 80: ...1 2 8 7 E Crankcase Bolt M6 17 10 1 0 7 2 E Rear balancer cover Bolt M6 4 12 1 2 8 7 Balancer lever Bolt M8 2 14 1 4 10 Balancer shaft pinch bolt M6 2 10 1 0 7 2 Plate Torx screw M6 2 12 1 2 8 7 LT C...

Страница 81: ...en the crankcase bolts further to reach the specified angle 120 in the proper tightening sequence 3 Tighten the connecting rod nuts to 20 Nm 2 0 m kg 14 ft lb and then tighten the connecting rod nuts...

Страница 82: ...2 22 SPEC TIGHTENING TORQUES Cylinder head tightening sequence Crankcase tightening sequence...

Страница 83: ...nut M18 125 12 5 90 Rear wheel axle pinch bolt M8 16 1 6 11 Brake torque rod M8 16 1 6 11 Rear brake caliper retaining bolt M10 27 2 7 19 Brake hose union bolt M10 30 3 0 22 Front brake master cylinde...

Страница 84: ...t rider footrest bracket and engine M10 49 4 9 35 Left rider footrest bracket sidestand bracket and frame M10 63 6 3 45 Ring gear bearing housing and final drive housing M10 40 4 0 29 Ring gear bearin...

Страница 85: ...s intake and exhaust M Valve stem ends intake and exhaust E Water pump impeller shaft E Oil pump rotors inner and outer E Oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Sta...

Страница 86: ...er mating surface Sealant Cylinder head cover Sealant Crankcase mating surface Sealant Clutch cover crankcase mating surface Sealant Generator cover crankcase mating surface Sealant Pickup coil rotor...

Страница 87: ...nd pivoting point and sliding surface LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivot bolt and contact surface LS Clutch lever pivot bol...

Страница 88: ...2 28 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil pump 3 Oil pipe 4 Relief valve 5 Oil filter cartridge 6 Main axle LUBRICATION POINTS AND LUBRICANT TYPES...

Страница 89: ...2 29 SPEC 1 Crankshaft 2 Main axle 3 Drive axle OIL FLOW DIAGRAMS...

Страница 90: ...2 30 SPEC 1 Oil nozzle 2 Main gallery bolt 3 Crankshaft OIL FLOW DIAGRAMS...

Страница 91: ...2 31 SPEC 1 Main axle 2 Drive axle 3 Oil delivery pipe OIL FLOW DIAGRAMS...

Страница 92: ...2 32 SPEC 1 Exhaust camshaft 2 Oil check bolt 3 Intake camshaft OIL FLOW DIAGRAMS...

Страница 93: ...2 33 SPEC 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil pump 5 Oil strainer 6 Oil pipe OIL FLOW DIAGRAMS...

Страница 94: ...2 34 SPEC 1 Crank pin 2 Crankshaft OIL FLOW DIAGRAMS...

Страница 95: ...2 35 SPEC 1 Rear balancer 2 Oil delivery pipe 3 Crankshaft 4 Front balancer 5 Crank pin OIL FLOW DIAGRAMS...

Страница 96: ...2 36 SPEC 1 Oil strainer 2 Oil delivery pipe 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil pan 8 Oil pipe 9 Oil pump OIL FLOW DIAGRAMS...

Страница 97: ...2 37 SPEC 1 Main axle 2 Drive axle 3 Middle drive shaft OIL FLOW DIAGRAMS...

Страница 98: ...2 38 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator COOLING SYSTEM DIAGRAMS...

Страница 99: ...2 39 SPEC 1 Water jacket joint 2 Oil cooler COOLING SYSTEM DIAGRAMS...

Страница 100: ...2 40 SPEC 1 Thermostat assembly 2 Coolant reservoir 3 Radiator 4 Oil cooler COOLING SYSTEM DIAGRAMS...

Страница 101: ...2 41 SPEC 1 Coolant reservoir 2 Radiator 3 Water pump COOLING SYSTEM DIAGRAMS...

Страница 102: ...ble 2 Brake cable 3 Clutch cable 4 Main switch lead 5 Headlight lead 6 Fuse box 7 Thermostat assembly breather hose 8 Coolant reservoir hose 9 Hazard switch 0 Rectifier regulator A Plate B Plunger con...

Страница 103: ...servoir hose and thermostat assembly breather hose through the left slit of the plate To the thermostat housing After passing the coolant reservoir hose through the two hose guides behind the plate pa...

Страница 104: ...ain fuse 8 Front turn signal lead 9 Spark plug lead 4 0 Spark plug lead 1 A Ignition coil lead 1 4 B Ignition coil 1 4 C Coolant reservoir D Coolant reservoir breather hose E Coolant reservoir hose F...

Страница 105: ...nnector so that the ignition coil lead can be turned outward Support the coolant reservoir breather hose with the hose holder attached to the coolant reser voir Pass the brake cable through the brake...

Страница 106: ...of the coolant reservoir hose should extend at least 50 mm 2 0 in from the hose guide Fasten the spark plug lead 1 and 4 at the number tag Pass the wire harness spark plug leads 1 2 3 and 4 through t...

Страница 107: ...2 47 SPEC CABLE ROUTING 1 Tail brake light lead...

Страница 108: ...fier regulator 5 Clutch cable 6 Fuel tank overflow hose 7 Fuel tank breather hose 8 Stator coil lead 9 Sidestand switch 0 Sidestand switch lead A Oil level switch lead B Brake cable C Coolant reservoi...

Страница 109: ...e frame Clamp the wire harness with the plastic band attached to the frame To the fuel tank Pass the stator coil lead at the fork of the wire harness Attach the clutch cable to the frame using the clu...

Страница 110: ...ten the tail brake light lead with a plastic band to the frame Pass the tail brake light lead between the rear cover and frame Pass the wire harness on the inside of the seat lock cable Support the wi...

Страница 111: ...ad 4 Headlight lead 5 Main switch lead 6 Throttle cable 7 Right handlebar switch lead 8 T bar 9 Spark plug lead 3 0 Spark plug lead 2 A Spark plug lead 1 B Spark plug lead 4 C Cable guide D Throttle p...

Страница 112: ...le cables through the hole on the right side of the frame To the lower right slit of the plate To the cylinder identification sensor To the fuel tank Pass the cylinder identification sensor lead throu...

Страница 113: ...eads 1 2 3 and 4 and the wire harness head light lead main switch lead right handlebar switch lead and left handlebar switch lead Install the thermostat heat protector throttle cables spark plug leads...

Страница 114: ...2 54 SPEC 1 Engine stop switch 2 Starting circuit cut off relay 3 Atmospheric pressure sensor 4 CYCLELOCK coupler 5 Seat lock cable CABLE ROUTING...

Страница 115: ...attached to the frame Pass the CYCLELOCK coupler through the inside of the storage box of the U lock Pass the CYCLELOCK coupler through the lead guide Pass the pressure sensor lead and engine stop swi...

Страница 116: ...4 Canister charge hose 5 Canister purge hose 6 Rollover valve 7 Canister To the left front of the fuel tank To the left rear of the fuel tank To the throttle bodies Align the white paint marks on the...

Страница 117: ...nce Check and adjust valve clearance when engine is cold Every 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Cr...

Страница 118: ...l leakage Repair if necessary 12 Steering bearings Check bearing assembly for looseness Moderately repack with lithium soap based grease every 12 000 mi 19 000 km or 18 months Repack 13 Brake and clut...

Страница 119: ...brake or clutch master cylinders caliper cylinders or clutch release cylin der always change the fluid Regularly check the brake and clutch fluid levels and fill the reser voirs as required Every two...

Страница 120: ...S AND FUEL TANK EAS00039 SEATS AND FUEL TANK SEATS Order Job Part Q ty Remarks Removing the seats Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 For installation reverse the re...

Страница 121: ...nel left and right 1 1 2 Bolt 2 3 Nut 1 4 Fuel sender coupler 1 5 Fuel pump coupler 1 6 Fuel tank overflow hose 1 7 Fuel tank breather hose 1 8 Hose holder 1 9 Fuel hose holder 2 10 Fuel hose 1 Refer...

Страница 122: ...Removing the T bar Remove the parts in the order listed Rider seat fuel tank Refer to SEATS AND FUEL TANK 1 Left rubber cover 1 2 Right rubber cover 1 3 T bar 1 4 Rubber sheet 1 For installation reve...

Страница 123: ...uel remain ing in it NOTE Before removing the hoses place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal lation surface...

Страница 124: ...oss pattern and to the specified torque FWD T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose holders CAUTION When installing the fuel hose make sure that it is secure...

Страница 125: ...el tank Refer to SEATS AND FUEL TANK Side covers left and right Refer to COWLINGS AND COVERS 1 Air shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Lean angle cut off switch 1 5 Tray 1 6 Fu...

Страница 126: ...rder Job Part Q ty Remarks 10 Air induction system hose 5 1 Disconnect 11 Clamp screw 4 Loosen 12 Air filter case 1 13 Air filter case breather hose 1 For installation reverse the removal procedure AI...

Страница 127: ...AND FUEL TANK 1 Left side cowling 1 2 Right side cowling 1 3 Front bottom cowling 1 4 Front turn signal connector left 2 5 Front turn signal connector right 2 6 Left inner panel front cowling 1 7 Fus...

Страница 128: ...front cowling assembly Remove the parts in the order listed 1 Windshield outer bracket 1 2 Windshield 1 3 Grommet 7 4 Windshield inner bracket 1 5 Rear view mirror left and right 2 6 Panel 1 7 Front c...

Страница 129: ...13 CHK ADJ 1 Order Job Part Q ty Remarks Removing the headlight assembly Remove the parts in the order listed 1 Headlight assembly 1 For installation reverse the removal procedure COWLINGS AND COVERS...

Страница 130: ...the parts in the order listed 1 Windshield drive unit 1 2 Windshield drive unit coupler 2 3 Meter assembly 1 4 Meter assembly coupler 1 5 Headlight relay 1 1 6 Headlight relay 2 1 7 Fuel injection sys...

Страница 131: ...Order Job Part Q ty Remarks Removing the covers Remove the parts in the order listed Seats Refer to SEATS AND FUEL TANK 1 Left side cover 1 2 Right side cover 1 3 Rear carrier 1 4 Rear cover 1 For ins...

Страница 132: ...be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK side cowlings front cowling a...

Страница 133: ...d when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve...

Страница 134: ...wise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise 7 Remove intake camshaft caps exhaust camshaft caps timing chain from the camshaft sprockets intake ca...

Страница 135: ...ded in order to reach the closest equiva lent to the original c Round off the original valve pad number according to the following table EXAMPLE Original valve pad number 148 thickness 1 48 mm Rounded...

Страница 136: ...d intake camshafts timing chain and camshaft caps NOTE Refer to INSTALLING THE CAMSHAFTS CAMSHAFTS in chapter 5 Lubricate the camshafts camshaft lobes and camshaft journals First install the exhaust c...

Страница 137: ...28 1 32 230 235 240 1 33 1 37 235 240 1 38 1 42 240 MEASURED CLEARANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 0...

Страница 138: ...roperly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand 2 Remove rider seat fuel tank T bar Refer to SEATS AN...

Страница 139: ...the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION Do not use the throttle valve adjusting screws to adjust the throt...

Страница 140: ...ee play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in 12 Remove engine tachometer vacuum gauge 13 Remove fuel tank 14...

Страница 141: ...minutes 2 Remove fuel tank side panels left and right fuel tank front mounting bolts 3 Lift up the front of the fuel tank 4 Attach inductive tachometer onto the spark plug lead of cylinder 1 5 Measure...

Страница 142: ...nt mounting bolts fuel tank side panels left and right Refer to SEATS AND FUEL TANK EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idli...

Страница 143: ...a or b until the specified throttle cable free play is obtained e Tighten the locknuts NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the...

Страница 144: ...seat Refer to SEATS AND FUEL TANK EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove rider seat fuel tank T bar Refer to SEATS AND FUEL TANK 2 Disconn...

Страница 145: ...a wire gauge Out of specification Regap 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install T bar fuel tank rider sea...

Страница 146: ...cylinder 1 3 Install fuel tank Refer to SEATS AND FUEL TANK 4 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check...

Страница 147: ...to all of the cylinders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Star...

Страница 148: ...ifference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 14 22 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces...

Страница 149: ...r Same as without oil Piston ring s valves cylinder head gasket or pis ton possibly defec tive Repair 10 Install spark plug 11 Connect spark plug cap 12 Install T bar fuel tank rider seat T R 13 Nm 1...

Страница 150: ...clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase NOTE _ API Service SE SF and SG type or equivalent e g SF SE SF SE CC SF SE SD Before...

Страница 151: ...laced perform the following procedure a Remove the left side cowling Refer to COWLINGS AND COVERS b Remove the oil filter cartridge 1 with an oil filter wrench 2 c Lubricate the O ring 3 of the new oi...

Страница 152: ...ed engine oil 9 Install engine oil filler cap 10 Start the engine warm it up for several min utes and then turn it off Quantity Total amount 4 9 L 4 31 Imp qt 5 18 US qt Without oil filter cartridge r...

Страница 153: ...IL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification T R Oil gallery bolt 20 Nm 2 0 m kg 14 ft lb...

Страница 154: ...stall main gallery bolt Pressure gauge 90890 03153 Oil pressure adapter B 90890 03124 Engine oil pressure 30 kPa 0 30 kg cm2 4 27 psi Engine speed Approx 1 000 1 100 r min Engine oil temperature 73 C...

Страница 155: ...dial with the arrow mark 2 on the clutch lever holder WARNING After adjusting the clutch lever position make sure the pin on the clutch lever holder is firmly inserted in the hole in the adjusting dia...

Страница 156: ...eful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch fluid may damage painted surfac...

Страница 157: ...the hose have disappeared 1 Bleed hydraulic clutch system a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir diaphragm c Connect a clear plastic hose...

Страница 158: ...ng the hydraulic clutch system check the clutch operation EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove seats Refer to SEATS AND FUEL TANK left side cover Refer to COWLINGS AND COVERS 2 Remove air...

Страница 159: ...ce and possible overheat ing NOTE When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 7 Install air shroud 8 In...

Страница 160: ...efer to SEATS AND FUEL TANK EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove rider seat fuel tank Refer to SEATS AND FUEL TANK air filter case Refer to AIR FILTER CASE 2 Check crankcase breather...

Страница 161: ...Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 3 Check tightening torque 4 Install side cowlings Refer to COWLINGS AND COVERS T R Exhaust pipe assembly and bra...

Страница 162: ...mum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec...

Страница 163: ...ing assembly Refer to COWLINGS AND COVERS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket joint 6 Cracks damage Replace Re...

Страница 164: ...he radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or...

Страница 165: ...es Mixing ratio 1 1 antifreeze water Quantity Total amount 3 2 L 2 82 Imp qt 3 38 US qt Coolant reservoir capacity 0 485 L 0 43 Imp qt 0 51 US qt From minimum to maximum level mark 0 15 L 0 13 Imp qt...

Страница 166: ...wash them with water Do not mix different types of antifreeze 12 Install radiator cap 13 Remove coolant reservoir cap cover 1 coolant reservoir cap 14 Fill coolant reservoir with the recommended cool...

Страница 167: ...make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake sys tem lever can indicate the presence of air in the brake syste...

Страница 168: ...1 to specification WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake...

Страница 169: ...luid level Below the minimum level mark a Add the recommended brake fluid to the proper level Front brake Rear brake WARNING Use only the designated brake fluid Other brake fluids may cause the rubber...

Страница 170: ...procedure applies to all of the brake pads 1 Operate the brake 2 Check front brake pad Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in ch...

Страница 171: ...ime c Install the right footrest bracket bolts Direction a Brake light comes on sooner Direction b Brake light comes on later T R Right footrest bracket bolt 28 Nm 2 8 m kg 20 ft lb EAS00131 CHECKING...

Страница 172: ...o enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding proce...

Страница 173: ...ten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic...

Страница 174: ...e final drive housing oil filler bolt 1 3 Check final drive oil level The final drive oil level should be to the bot tom brim 1 of the filler hole Below the bottom brim Add the recom mended final driv...

Страница 175: ...fer to CHECKING THE FINAL DRIVE OIL LEVEL Quantity 0 2 L 0 18 Imp qt 0 21 US qt EAS00147 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the motorcycle on a level surface WARNING Securely support the...

Страница 176: ...turn and then tighten it to specification with a steering nut wrench WARNING Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the...

Страница 177: ...ebars washer steering stem nut 7 Tighten upper bracket pinch bolts T R 115 Nm 11 5 m kg 85 ft lb T R 34 Nm 3 4 m kg 24 ft lb EAS00150 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface...

Страница 178: ...ger of it falling over Spring preload CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the a...

Страница 179: ...17 clicks out Standard 12 clicks out Maximum 1 click out Compression damping CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust compression damping a Turn the adjusting scr...

Страница 180: ...direction a or b b Adjust the adjusting lever to HARD or SOFT Position a Spring preload is increased suspension is harder Position b Spring preload is decreased suspension is softer Rebound damping C...

Страница 181: ...nsion must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an a...

Страница 182: ...d pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and repla...

Страница 183: ...inting in the direction of wheel rotation Align the mark 5 with the valve installation point Manufacturer Model Size METZELER MEZ4J FRONT 120 70 ZR17 M C 58W BRIDGESTONE BT020F N 120 70 ZR17 M C 58W M...

Страница 184: ...heath Damage Replace 2 Check cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recom...

Страница 185: ...STAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting poi...

Страница 186: ...te as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTER...

Страница 187: ...ket tester to the battery termi nals NOTE The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No...

Страница 188: ...re connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full conta...

Страница 189: ...rd charg ing amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable t...

Страница 190: ...hes 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Thi...

Страница 191: ...y terminals 10 Install right inner panel front cowling Refer to COWLINGS AND COVERS Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fu...

Страница 192: ...f the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Items Amperage rating Q ty Main fuse 50 A 1 Headlight fuse 25 A 1 Radiator fan motor fuse 15...

Страница 193: ...ibly cause a fire 4 Install front right inner panel front cowling right inner panel front cowling left inner panel front cowling Refer to COWLINGS AND COVERS EAS00183 REPLACING THE HEADLIGHT BULBS The...

Страница 194: ...nd the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Attach headlight bulb holder 7 Install he...

Страница 195: ...zontally a Turn the adjusting screw 1 in direction a or b Left headlight Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headligh...

Страница 196: ...3 80 CHK ADJ ADJUSTING THE HEADLIGHT BEAMS...

Страница 197: ...ce the motorcycle on a suitable stand so that the front wheel is elevated 1 Brake caliper left and right 2 Refer to REMOVING INSTALLING THE FRONT WHEEL 2 Wheel axle pinch bolt 1 Loosen 3 Front wheel a...

Страница 198: ...WHEEL AND BRAKE DISCS EAS00518 Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disasse...

Страница 199: ...ove left brake caliper right brake caliper NOTE Do not squeeze the brake lever when remov ing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front w...

Страница 200: ...seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c...

Страница 201: ...ing the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the...

Страница 202: ...fication f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE EAS00545 INSTALLING THE FRONT WHEEL The follow...

Страница 203: ...nstalled 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 X mark at the b...

Страница 204: ...rn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balance...

Страница 205: ...s in the order listed NOTE Place the motorcycle on a suitable stand so that the rear wheel is elevated 1 Brake torque rod nut bolt 1 1 Refer to INSTALLING THE REAR WHEEL 2 Wheel axle nut 1 3 Wheel axl...

Страница 206: ...rear wheel Remove the parts in the order listed 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 2 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Sp...

Страница 207: ...levated 2 Remove brake caliper bracket NOTE Do not depress the brake pedal when remov ing the brake caliper bracket with brake cali per 3 Remove rear wheel NOTE Move the rear wheel to the right to sep...

Страница 208: ...2 Tighten brake torque rod nut wheel axle nut wheel axle pinch bolt T R 30 Nm 3 0 m kg 22 ft lb T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb EAS00575 ADJUSTING THE REAR WHEEL STATIC BALAN...

Страница 209: ...ont brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake hose holder bolt 1 2 Brake caliper bolt 2 3 Brake pad clip 2 4 Brake pad...

Страница 210: ...AS00578 REAR BRAKE PADS Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad 2 3 Brake pad shim 2 4 Bleed screw 1 For installati...

Страница 211: ...y clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming...

Страница 212: ...install new brake pads brake pad shims 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 b...

Страница 213: ...evel Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583...

Страница 214: ...d 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 pis...

Страница 215: ...the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake s...

Страница 216: ...oving the front brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake maste...

Страница 217: ...bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder holder 1 10 Brake master cylinder 1 11 Front...

Страница 218: ...Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For as...

Страница 219: ...n the order listed Side cover right Refer to COWLINGS AND COVERS in chapter 3 Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphra...

Страница 220: ...Part Q ty Remarks 9 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING THE REAR BRAKE MASTER CYLINDER 10 Copper washer 2 11 Brake hose 1 Disconnect 12 Cotter pin 1 13 Pin 1 14 Brake master cylinder 1 For...

Страница 221: ...Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder 1...

Страница 222: ...em 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE RE...

Страница 223: ...id delivery passages brake master cylinder body Obstruction Blow out with compressed air Front Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace Front Rear 3 Check rear brake flui...

Страница 224: ...ponents 1 Install brake master cylinder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a in the right...

Страница 225: ...uids 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 har...

Страница 226: ...SYSTEM in chapter 3 EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers 1 brake hose 2 union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle ope...

Страница 227: ...ervoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any sp...

Страница 228: ...4 32 CHAS FRONT AND REAR BRAKES 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3...

Страница 229: ...order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Brake hose holder bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS...

Страница 230: ...rder listed 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 Brake pad brake pad shim 2 2 5 Brake caliper piston 4 Refer...

Страница 231: ...rder listed Brake fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Retaining bolt 2 Loosen 5 Brake torqu...

Страница 232: ...r Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad brake pad shim 2 2 3 Brake pad spring 2 4 Rear brake caliper bracket 1 5 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BR...

Страница 233: ...ke hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blo...

Страница 234: ...rake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper piston 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out th...

Страница 235: ...brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals Front Rear Recommende...

Страница 236: ...ll cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copp...

Страница 237: ...e 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...

Страница 238: ...ULIC BRAKE SYSTEM in chapter 3 EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new b...

Страница 239: ...union bolt 3 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose onto the brake caliper make sure the brak...

Страница 240: ...ading 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...

Страница 241: ...4 45 CHAS FRONT AND REAR BRAKES 9 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3...

Страница 242: ...emoving the clutch master cylin der Remove the parts in the order listed Clutch fluid Drain 1 Clutch master reservoir cap 1 2 Clutch master reservoir diaphram holder 1 3 Clutch master reservoir diaphr...

Страница 243: ...INSTALLING THE CLUTCH MASTER CYLINDER 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 Refer to ASSEMBLING AND INSTALLING THE CLUTCH MASTER C...

Страница 244: ...the clutch master cylinder Remove the parts in the order listed 1 Clutch master cylinder push rod 1 2 Dust seal 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder 1 For...

Страница 245: ...components Clutch fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serio...

Страница 246: ...eplace the clutch mas ter cylinder clutch fluid delivery passage clutch master cylinder body Obstruction Blow out with compressed air 2 Check clutch master cylinder 1 clutch master cylinder kit 2 Rust...

Страница 247: ...lutch fluid Brake fluid DOT 4 1 Install clutch master cylinder 1 NOTE Install the clutch master cylinder holder with the UP mark facing up Align the end of the clutch master cylinder holder with the p...

Страница 248: ...luid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu...

Страница 249: ...fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 6 Check clutch lever operation Soft or spongy fee...

Страница 250: ...Remove the parts in the order listed Clutch fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutc...

Страница 251: ...Remove the parts in the order listed 1 Clutch release cylinder piston 1 Refer to DISASSEMBLING THE CLUTCH RELEASE CYLINDER 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4...

Страница 252: ...lly 2 Remove clutch release cylinder piston 1 clutch release cylinder spring 2 clutch release cylinder piston seal 3 a Blow compressed air into the clutch hose joint opening a to force out the piston...

Страница 253: ...ch release cylinder piston 2 Rust scratches wear Replace the clutch release cylinder and clutch release cylinder piston as a set EAS00315 ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER 1 Instal...

Страница 254: ...erformance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION Clutch...

Страница 255: ...4 59 CHAS 5 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 HYDRAULIC CLUTCH...

Страница 256: ...he front fork legs Front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Collar 2 3 Collar 2 4 Upper bracket pinch bolt 1...

Страница 257: ...rder listed The following procedure applies to both of the front fork legs 1 Cap bolt O ring 1 1 Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 2 Damper adjusting rod 1 3 Nut 1 4 Spacer 1 5 Was...

Страница 258: ...DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS C Inner tube 1 D Oil seal 1 Refer to ASSEMBLING THE FRONT FORK LEGS E Seal spacer 1 F Outer tube bushing 1 G Inner tube bushing 1 H Oil flow stopper 1 I O...

Страница 259: ...suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolts 3 WARNING Before loosening the upper and lower bracket pinch bolts support t...

Страница 260: ...amper rod assembly bolt While holding the damper rod with the damper rod holder 2 loosen the damper rod assembly bolt 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the br...

Страница 261: ...free length a Out of specification Replace Spring free length 261 mm 10 28 in 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stoppe...

Страница 262: ...en assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure all of the components ar...

Страница 263: ...kg 25 ft lb 4 Install outer tube bushing 1 with the fork seal installer 2 Fork seal installer YM 01442 New 5 Install seal spacer oil seal 1 with the fork seal driver CAUTION Make sure the numbered sid...

Страница 264: ...the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork...

Страница 265: ...top of the inner tube with the inner tube fully compressed and without the spring 100 mm 3 94 in 14 Install nut 1 damper adjusting rod 2 cap bolt 3 a Install the nut 1 and finger tighten it b Install...

Страница 266: ...Make sure that the inner tube end is flush with the top of the upper bracket Temporarily tighten the upper and lower bracket pinch bolts WARNING Make sure the brake hoses are routed prop erly 2 Tight...

Страница 267: ...ont fender Install the collar 2 from the inside of the front fender When installing the front fender make sure that there is no dirt between the front fender and front fork T R 6 Nm 0 6 m kg 4 3 ft lb...

Страница 268: ...ebar Remove the parts in the order listed 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Clutch master cylinder 1 4 Left handlebar...

Страница 269: ...Front brake light switch connector 2 Disconnect 2 Brake master cylinder holder 1 Refer to REMOVING INSTALLING THE HANDLEBARS 3 Brake master cylinder 1 4 Grip end 1 5 Throttle cable housing 1 6 Throttl...

Страница 270: ...ed air between the left handle bar and the handlebar grip and gradually push the grip off the handlebar 3 Remove throttle cable housing 1 throttle grip 2 NOTE While removing the throttle cable housing...

Страница 271: ...in the right handlebar 3 Install throttle grip 1 throttle cable housing 2 throttle cables grip end NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and insta...

Страница 272: ...dlebar grip grip end a Apply a thin coat of rubber adhesive onto the left end of the left handlebar b Slide the handlebar grip over the left end of the left handlebar c Wipe off any excess rubber adhe...

Страница 273: ...the slit in the clutch master cylinder holder with the punch mark a in the left han dlebar T R 10 Nm 1 0 m kg 7 2 ft lb 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PL...

Страница 274: ...s in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebars Refer to HANDLEBARS 1 Lead guide 2 2 Main switch coupler 2 Disconnect Refer to INS...

Страница 275: ...LOWER BRACKET and INSTALLING THE STEERING HEAD 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Bearing cover 1 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearin...

Страница 276: ...1 with the special tool 2 WARNING Securely support the lower bracket so that there is no danger of it falling Spanner wrench YU 33975 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races...

Страница 277: ...bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EA...

Страница 278: ...racket steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK NOTE Temporarily tighten the lower and upper bracket pinch bolts 5 Tighten steerin...

Страница 279: ...r Job Part Q ty Remarks Removing the rear shock absorber assembly and relay arm Remove the parts in the order listed Rear wheel Refer to REAR WHEEL AND BRAKE DISC Mufflers exhaust pipe Refer to ENGINE...

Страница 280: ...64 Nm 6 4 m kg 46 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 48 Nm 4 8 m kg 35 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib Order Job Part Q ty Remarks 9 Relay arm 1 10 Collar 1 11 Collar...

Страница 281: ...use an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping performance EAS00688 DISPOSING OF A REA...

Страница 282: ...swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check rear shock absorber rod Bends damage Replac...

Страница 283: ...s 2 Install bearing 1 2 to the relay arm Recommended lubricant Lithium soap base grease Installed depth a 4 0 mm 0 16 in Installed depth b 4 5 mm 0 18 in EAS00698 INSTALLING THE REAR SHOCK ABSORBER AS...

Страница 284: ...chapter 5 Rear wheel Refer to REAR WHEEL AND BRAKE DISC Final drive assembly universal joint Refer to SHAFT DRIVE Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1 Ri...

Страница 285: ...s 9 Oil seal 2 10 Bearing 2 Refer to INSTALLING THE SWINGARM 11 Spacer 1 12 Oil seal 1 13 Bushing 1 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Spacer 1 18 Bearing 1 Refer to INSTALLING THE SWINGARM Fo...

Страница 286: ...nut b Measure the swingarm side play by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bushing and bear ings d Check the swingarm vertica...

Страница 287: ...ot shaft spacers bushing bearings Recommended cleaning solvent Kerosene 4 Check spacers bushing oil seals Damage wear Replace bearings Damage pitting Replace EAS00712 INSTALLING THE SWINGARM 1 Lubrica...

Страница 288: ...4 92 CHAS 3 Install bearing 1 to the swingarm Installed depth a 4 0 mm 0 16 in SWINGARM...

Страница 289: ...rky movement during acceleration deceleration or sustained speeds not to be confused with engine surg ing or transmission related movements 2 A rolling rumble noticeable at low speeds a high pitched w...

Страница 290: ...tion Diagnosis Possible incorrect reassembly or too little gear backlash WARNING Insufficient gear backlash is extremely destructive to the gear teeth If a test ride following reassembly indicates the...

Страница 291: ...d YES Replace the wheel bearing Refer to FRONT WHEEL AND BRAKE DISCS NO Place the motorcycle on a suitable stand so that the rear wheel is elevated and then spin the rear wheel Is the wheel bearing da...

Страница 292: ...Check shaft drive housing for oil leaks a Thoroughly clean the entire motorcycle and then completely dry it b Apply a leak locating compound or dry pow der spray to the shaft drive c Test ride the mo...

Страница 293: ...overtighten the bolt c Install the final drive gear lash tool 2 and dial gauge 3 a Dial gauge plunger contact point 60 mm 2 36 in d Gently rotate the gear coupling from engagement to engagement e Reco...

Страница 294: ...t the suitable shim s and thrust washer with the following chart b If it is necessary to increase the ring gear backlash by more than 0 2 mm reduce the thrust washer thickness by 0 2 mm for every 0 2...

Страница 295: ...arance a Out of specification Adjust 1 Stopper bolt 2 Ring gear 3 Install ring gear bearing housing along with the ring gear Ring gear to stopper bolt clear ance 0 30 0 60 mm 0 01 0 02 in EAS00722 ADJ...

Страница 296: ...AUTION The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Apply LOCTITE onto the stopper bolt 4 Measure ring gear to stopper bolt clearance NOTE If the ring g...

Страница 297: ...g the final drive assembly Remove the parts in the order listed Final gear oil Drain Rear wheel Refer to REAR WHEEL AND BRAKE DISC 1 Final drive assembly 1 Refer to INSTALLING THE UNIVERSAL JOINT AND...

Страница 298: ...order listed Final drive assembly 1 Shift arm 1 Refer to INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY 2 Left footrest bracket 1 Refer to REMOVING THE LEFT FOOTREST BRACKET 3 Dust cover 1 4...

Страница 299: ...arts in the order listed 1 Circlip 2 2 Oil seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing oil seal 1 1 6 Dust cover 1 Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 Ring...

Страница 300: ...EMBLY and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR C Gear coupling 1 D Bearing retainer oil seal 1 1 Left hand threads E Final drive pinion gear bearing 1 1 F Final drive pinion gear shim s...

Страница 301: ...THE FINAL DRIVE ASSEMBLY 1 Remove ring gear bearing housing nuts ring gear bearing housing bolts NOTE Working in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos...

Страница 302: ...new bearings CAUTION The final drive pinion gear should only be removed if ring gear replacement is neces sary NOTE Lightly tap on the end of the final drive pinion gear with a soft hammer Piston bea...

Страница 303: ...ifficult procedure and is rarely neces sary 4 Install bearing a Heat the final gear case to approximately 150 C 302 F b Install the bearing outer races with a socket or appropriate tool that matches t...

Страница 304: ...e final drive housing and the drive pinion gear 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b To find final drive pinion gear shim thickness A use the following formula Where a a n...

Страница 305: ...mm 0 02 in final drive pinion gear shim Final drive pinion gear shims Thickness mm 0 30 0 40 0 50 Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 c To find ring gear shim thickness B use the follo...

Страница 306: ...culated ring gear shim thick ness is 0 51 mm 0 02 in Shim sizes are supplied in the following thick nesses Since the ring gear shims are only available in 0 10 mm 0 004 in increments round off the hun...

Страница 307: ...n bearing retainer remover YM 04050 T R 110 Nm 11 0 m kg 80 ft lb 3 Install gear coupling 1 nut 2 with the coupling gear holder 3 CAUTION Apply LOCTITE to the nut 4 Lock the threads with a drift punch...

Страница 308: ...sti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bearing housing along with the ring gear g If the ring gear to thrust washer clearance is out of...

Страница 309: ...ft splines with the driven yoke of the universal joint 3 Tighten final drive assembly nuts Recommended lubricant Lithium soap base grease T R 42 Nm 4 2 m kg 30 ft lb 4 Install shift arm 1 NOTE Align t...

Страница 310: ...isted Seats fuel tank T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in cha...

Страница 311: ...rottle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 Air cut off valve assembly hoses reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Thermostat assembly Refer to THERMOSTAT in chapter 6 E...

Страница 312: ...switch coupler 1 Disconnect 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect 6 Stator assembly coupler 1 Disconnect 7 Oil level sensor connector 1 Disconnect 8 Crankshaft position sensor...

Страница 313: ...m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE Place a sui...

Страница 314: ...T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Ord...

Страница 315: ...pinch bolt A NOTE Tighten the spacer bolt 2 to specification with a frame spanner socket B When tightened the spacer bolt 2 should be flat against the engine surface Frame spanner socket YM 01471 T R...

Страница 316: ...lb 5 Temporarily tighten the bolt engine bracket 1 and frame 1 and bolts engine bracket 1 and engine 2 NOTE When temporarily tightened the bolts 1 2 should be flat against the engine and frame surface...

Страница 317: ...cylinder head cover Remove the parts in the order listed Reed valves Refer to AIR INDUCTION SYSTEM in chapter 7 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Spark plug 4 2 Cylinde...

Страница 318: ...EM in chapter 7 Pickup coil rotor cover Refer to PICKUP COIL ROTOR 1 Timing chain tensioner 1 Refer to REMOVING INSTALLING THE CAMSHAFTS 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exh...

Страница 319: ...5 10 ENG Order Job Part Q ty Remarks 10 Timing chain guide exhaust side 1 11 Pin 1 12 Timing chain guide intake side 1 For installation reverse the removal procedure CAMSHAFTS...

Страница 320: ...n the pickup coil rotor with the crankcase mating surface b NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Loosen cap bolt 1 3 Remove timing...

Страница 321: ...mensions a and b Out of specification Replace the cam shaft Minimum cam lobe dimensions Intake camshaft a 32 05 mm 1 2618 in b 23 997 mm 0 9448 in Exhaust camshaft a 32 95 mm 1 2972 in b 24 897 mm 0 9...

Страница 322: ...nal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journa...

Страница 323: ...ing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS00217 INSTALLING THE CAMSHAFTS 1 Install exhaust cams...

Страница 324: ...the timing chain start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side Make sure the marks e on the timing chain sprockets are parallel with th...

Страница 325: ...T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE Mak...

Страница 326: ...turns clockwise 7 Check T mark a Make sure the T mark a on the pickup coil rotor is aligned with the crankcase mat ing surface b camshaft holes c Make sure the holes c in the cylinder 4 cam are aligne...

Страница 327: ...Apply bond T1541 1 onto the mating sur faces of the cylinder head cover and cylinder head cover gasket Apply bond YGK8624 C1 2 onto the mating surfaces of the cylinder head cover gasket and cylinder h...

Страница 328: ...Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Radiator Refer to RADIATOR in chapter 6 Exhaust pipe assembly Refer to ENGINE Camshafts Refer to CAMSHAFTS 1 Cylin...

Страница 329: ...Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Elim...

Страница 330: ...d NOTE Pass the timing chain through the timing chain cavity 3 Tighten cylinder head bolts M10 1 NOTE Do not reuse the cylinder head bolts The tightening procedure of the cylinder head bolts is angle...

Страница 331: ...the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and per form the procedure again CAUTION Do not use a torque wrench...

Страница 332: ...valves and valve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 16 Refer to REMOVING INSTALLING THE VALVES 2 Valve pad 16 3 Valve cotter 32 4 Upper s...

Страница 333: ...roperly seal 1 Remove valve lifter 1 valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve for leakage L...

Страница 334: ...ment 3 Valve spring compressor set YM 03153 Attachment YM 04108 4 Remove upper spring seat 1 valve spring 2 valve 3 oil seal 4 lower spring seat 5 NOTE Identify the position of each part very carefull...

Страница 335: ...valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1...

Страница 336: ...thickness Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in 6 Measure valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the...

Страница 337: ...and valve face contacted one another the blueing will have been removed Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 06...

Страница 338: ...ff all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the va...

Страница 339: ...ing force installed 13 9 16 1 kg at 33 mm 30 6 35 5 lb at 1 30 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Maximum valve spring tilt 1 7 mm 0 07 in EAS00242 CHECKING...

Страница 340: ...an oil stone 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install lower spring seat 1 oil seal 2 valve 3 valve spring 4 upper spr...

Страница 341: ...valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve 6 Lubricate valve pad valve lifter with t...

Страница 342: ...r listed Fuel tank seats T bar rubber seat Refer to SEATS AND FUEL TANK in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE...

Страница 343: ...starter clutch idle gear 1 7 Generator rotor 1 Refer to REMOVING INSTALLING THE GENERATOR 8 Woodruff key 1 9 Starter clutch gear 1 Refer to REMOVING INSTALLING THE STARTER CLUTCH 10 Starter clutch 1 F...

Страница 344: ...b Part Q ty Remarks Removing the stator assembly Remove the parts in the order listed 1 Lead holder 1 Refer to INSTALLING THE GENERA TOR 2 Stator assembly 1 For installation reverse the removal proced...

Страница 345: ...r all of the bolts are fully loosened remove them 2 Remove generator rotor bolt 1 washer NOTE While holding the generator rotor 2 with the primary sheave holder 3 loosen the genera tor rotor bolt Prim...

Страница 346: ...HE STARTER CLUTCH 1 Check starter clutch rollers 1 Damage wear Replace 2 Check starter clutch idle gear 1 starter clutch gear 2 Burrs chips roughness wear Replace the defective part s 3 Check starter...

Страница 347: ...freely otherwise the starter clutch is faulty and must be replaced EAS00355 INSTALLING THE STARTER CLUTCH 1 Install starter clutch starter clutch bolts 1 NOTE While holding the generator rotor with t...

Страница 348: ...he generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the generator rotor bolt and washer with engine oil 4...

Страница 349: ...pter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Side covers front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3...

Страница 350: ...nkshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 Refer to INSTALLING THE PICKUP COIL ROTOR 6 Pickup coil rotor 1 Refer to REMOVING INSTALLING THE PICKUP COIL ROTOR For insta...

Страница 351: ...hem 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the primary sheave holder 4 remove the pickup coil rotor bolt Primary sheave holder YS 01...

Страница 352: ...pickup coil rotor bolt Primary sheave holder YS 01880 A T R 45 Nm 4 5 m kg 32 ft lb 3 Apply sealant onto the crankshaft position sensor lead grommet Quick Gasket ACC 11001 05 01 4 Install pickup coil...

Страница 353: ...ty Remarks Removing the clutch cover Remove the parts in the order listed Right side cowling Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1...

Страница 354: ...IC CLUTCH in chap ter 4 Rear balancer Refer to BALANCERS 1 Oil guide plate 1 Refer to REMOVING INSTALLING THE CLUTCH 2 Clutch spring plate retainer 1 3 Clutch spring plate 1 4 Clutch spring plate seat...

Страница 355: ...OVING INSTALLING THE CLUTCH 13 Clutch boss 1 14 Wire circlip 1 15 Clutch plate 2 1 16 Friction plate 3 1 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Thrust washer 1 20 Spacer 1 21 Clut...

Страница 356: ...aighten the lock washer tab 4 Loosen clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder YM 91042 5 Remove clu...

Страница 357: ...tallation Insert two 5 mm 0 20 in bolts 2 into the spacer and then remove the spacer by pull ing on the bolts EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fricti...

Страница 358: ...a set Maximum Maximum clutch plate warpage 0 1 mm 0 004 in EAS00283 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate 1 Damage Replace 2 Check clutch spring plate seat 2 Damage Replace EAS0...

Страница 359: ...KING THE CLUTCH PUSH RODS 1 Check O ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks damage wear Replace the defec tive part s 2 Measure long clutch push rod bending Out of specific...

Страница 360: ...of the holes of the clutch housing and primary driven gear and then rotate the inner pri mary driven gear until both primary driver gears are aligned The teeth of both primary driven gears must be al...

Страница 361: ...de of the nut Universal clutch holder YM 91042 New T R 90 Nm 9 0 m kg 65 ft lb 6 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Recommended lubricant Li...

Страница 362: ...plate seat 2 clutch spring plate 3 clutch spring plate retainer 4 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 11 Install rear balancer weight Refer to BALANCERS T R 8 Nm...

Страница 363: ...ft shaft Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Clutch housing Refer to CLUTCH 1 Oil baffle plate 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft...

Страница 364: ...Job Part Q ty Remarks 6 Stopper lever spring 1 Refer to INSTALLING THE SHIFT SHAFT 7 Stopper lever 1 8 Circlip 1 9 Collar 1 10 Shift shaft spring stopper 1 For installation reverse the removal procedu...

Страница 365: ...per lever stopper lever spring 2 Damage wear Replace EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stoppe...

Страница 366: ...5 57 ENG 3 Install shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm T R 10 Nm 1 0 m kg 7 2 ft lb SHIFT SHAFT...

Страница 367: ...bly Refer to ENGINE Air filter case Refer to AIR FILTER CASE in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Sidestand 1 2 Oil level switch connector 1 Disconnect 3 Oil l...

Страница 368: ...Q ty Remarks 9 Oil strainer 1 Refer to INSTALLING THE OIL STRAINER 10 Dowel pin 2 11 Oil pump 1 Refer to INSTALLING THE OIL PUMP 12 Relief valve assembly 1 For installation reverse the removal procedu...

Страница 369: ...ing the oil pump Remove the parts in the order listed 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 shaft 1 8 Oil pump housing 1 Fo...

Страница 370: ...Check oil pump shaft 1 oil pump housing 2 oil pump housing cover 3 Cracks damage wear Replace the defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing...

Страница 371: ...IL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS00368 CHEC...

Страница 372: ...il pump turns smoothly T R 12 Nm 1 2 m kg 8 7 ft lb LT EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer cover must point towards the front of the engi...

Страница 373: ...5 64 ENG WARNING Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil OIL PAN AND OIL PUMP...

Страница 374: ...N AND OIL PUMP 1 Left middle gear cover 1 2 Left middle gear cover gasket 1 3 Dowel pin 2 4 Right middle gear cover 1 5 Bearing 1 6 Middle driven shaft end cover 1 7 Oil seal 1 8 Middle driven pinion...

Страница 375: ...ASSEMBLY 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 Refer to REMOVING THE MIDDLE GEAR and INSTALLING THE...

Страница 376: ...Remove the parts in the order listed 1 Spring retainer 2 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVE SHAFT ASSEMBLY 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1...

Страница 377: ...the order listed 1 Middle driven pinion gear nut 1 2 Middle driven shaft 1 3 Middle driven pinion gear 1 4 Bearing retainer 1 Refer to DISASSEMBLING ASSEM BLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 Bear...

Страница 378: ...e holding the middle drive shaft 2 3 Straighten the lock washer tab 4 Loosen middle drive shaft nut 1 NOTE While holding the middle drive shaft 2 5 Straighten the punched point of the middle drive sha...

Страница 379: ...ing compressor push plate YM 33286 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Straighten the punched point of the bearing retainer 2 Loosen bearing retainer 1 with the bearing retainer wrench 2...

Страница 380: ...seal Damage Replace the defective part s EAS00440 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install spring retainers 1 NOTE While compressing the spring with the spring compressor push plate 2 ins...

Страница 381: ...VE SHAFT ASSEMBLY 1 Install middle drive shaft shim bearing bearing retainer 1 with the middle drive shaft retainer wrench 2 NOTE Lock the threads on the bearing retainer by staking them with a center...

Страница 382: ...iddle driven shaft assembly 1 middle driven shaft shims 2 middle driven shaft bearing housing bolts NOTE Finger tighten the middle driven shaft housing bolts 2 Tighten middle driven shaft nut 1 NOTE W...

Страница 383: ...lb EAS00449 MEASURING THE MIDDLE GEAR BACKLASH 1 Measure middle gear backlash Out of specification Refer to ADJUST ING THE MIDDLE GEAR BACKLASH a Install the gear lash measurement tool 1 as shown b Ma...

Страница 384: ...ACKLASH 1 Loosen middle driven shaft bearing housing bolts 2 Remove shim s 3 Tighten middle driven shaft bearing housing bolts CAUTION Do not overtighten the middle driven shaft bearing housing bolts...

Страница 385: ...ng housing should be approximately 2 mm 0 08 in when mea sured with a thickness gauge 1 4 Hold the middle drive shaft 1 5 Turn middle driven shaft NOTE While carefully tightening the middle driven sha...

Страница 386: ...ere fore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm 0 016 in shim Shims are supplied in the following thick nesses Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9...

Страница 387: ...at has had its respective thickness calculated from infor mation marked on the crankcase and the end of the middle drive gear 1 Middle drive gear shim thickness A 2 Middle drive gear shim thickness B...

Страница 388: ...gear which is added to the nominal size 34 e Measured value f a numeral on the upper crankcase near the main bearing selection numbers and which is added to the nominal size 88 Example If the middle d...

Страница 389: ...5 80 ENG Shims are supplied in the following thick nesses Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive shaft shim Thickness mm 0 10 0 15 0 30 0 40 0 50 0 60 MIDDLE GEAR...

Страница 390: ...listed Engine Refer to ENGINE Cylinder head Refer to CYLINDER HEAD Generator rotor Refer to GENERATOR AND STARTER CLUTCH Pickup coil rotor Refer to PICKUP COIL ROTOR Stopper lever Refer to SHIFT SHAF...

Страница 391: ...2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Collar 1 6 Spacer 1 7 Neutral switch 1 8 Speed sensor 1 9 Lower crankcase 1 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE 10 Dowel...

Страница 392: ...t Q ty Remarks Removing the oil baffle plates and bearings Remove the parts in the order listed Connecting rod assemblies Refer to CONNECTING RODS AND PISTONS Crankshaft crankshaft journal bearings Re...

Страница 393: ...0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 12 Nm 1 2 m kg 8 7 ft Ib Order Job Part Q ty Remarks 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter bolt 1 11 Lower crankcase...

Страница 394: ...crankcase indicate the crankcase tightening sequence 2 Place the engine upside down 3 Remove lower crankcase CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por...

Страница 395: ...nd crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean...

Страница 396: ...camshaft sprockets as a set oil pump drive chain 2 Damage stiffness Replace the oil pump drive chain oil pump drive sprocket and oil pump shaft as a set 2 Check oil pump drive sprocket Cracks damage...

Страница 397: ...n 2 3 mm 0 08 0 12 in of the crankshaft journal bear ings 3 Install dowel pins Quick Gasket ACC 11001 05 01 4 Set the shift drum assembly and transmis sion gears in the neutral position 5 Install lowe...

Страница 398: ...mm bolts U New 7 Tighten crankcase bolts 1 0 NOTE Do not reuse crankcase bolts 1 0 The tightening procedure of crankcase bolts 1 0 is angle controlled therefore tighten the bolts using the following...

Страница 399: ...ure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagonal bolt note that the angle from on...

Страница 400: ...r listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 Refer to REMOVING THE CONNECT ING RODS AND PISTONS and INSTALLING THE CONNECTING RODS AND PISTONS 2 Big end lower bearing 4 3 Pist...

Страница 401: ...ace 2 Remove piston pin clips 1 piston pin 2 piston 3 connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the p...

Страница 402: ...ngs as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cyl...

Страница 403: ...iston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 020 0 045 mm 0 0008 0 0018 in Limit 0 012 mm 0 0005 in EAS00263 CHECKING THE PISTON RINGS 1 Measure p...

Страница 404: ...the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 35 0 45 mm 0 014 0 018 in Limit 0 70 mm 0 028 in 2nd ring 0 75 0 85 mm 0 030 0 033 in Limit 1 20 mm...

Страница 405: ...cification Replace the piston Piston pin bore diameter in the piston 19 004 19 015 mm 0 7482 0 7486 in Limit 19 045 mm 0 7498 in 4 Calculate piston pin to piston clearance Out of specification Replace...

Страница 406: ...aring into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting r...

Страница 407: ...rings 2 Select big end bearings P1 P4 NOTE The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to...

Страница 408: ...Install piston 1 connecting rod 2 piston pin 3 piston pin clip 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod left when the arrow mark b on the piston i...

Страница 409: ...ricant Recommended lubricant Engine oil 7 Install big end bearings connecting rod assembly 1 into the cylinder and onto the crankshaft pin connecting rod cap onto the crankshaft pin NOTE Align the pro...

Страница 410: ...WARNING Replace the connecting rod bolts and nuts with new ones Clean the connecting rod bolts and nuts NOTE The tightening procedure of the connecting rod nuts is angle controlled therefore tighten...

Страница 411: ...hten it Replace the nut with a new one and per form the procedure again CAUTION Do not use a torque wrench to tighten the nut to the specified angle Tighten the nut until it is at the specified angle...

Страница 412: ...ts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 Refer to REMOVING INSTALLING THE CRANKSHAFT 2 Crankshaft journal lo...

Страница 413: ...EAS00396 CHECKING THE CRANKSHAFT 1 Measure crankshaft runout Out of specification Replace the crank shaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check crankshaft journal surfaces crankshaft pin...

Страница 414: ...crankshaft jour nal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 2 on each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the cranksh...

Страница 415: ...rs stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use th...

Страница 416: ...gs into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in its or...

Страница 417: ...ift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Drive axle assembly 1 Refer to INSTALLING THE TRANSMIS SION 2 Bearing 1 3 Washer 1 4 Shift drum retainer 1 5 Long...

Страница 418: ...Q ty Remarks 10 Shift drum assembly 1 Refer to INSTALLING THE TRANSMIS SION 11 Shift fork C 1 12 Main axle assembly 1 Refer to REMOVING INSTALLING THE TRANSMISSION For installation reverse the remova...

Страница 419: ...e main axle assem bly Remove the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circ...

Страница 420: ...5 111 ENG New M M M M New Order Job Part Q ty Remarks A Main axle 1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For assembly reverse the disassembly procedure TRANSMISSION...

Страница 421: ...rks Disassembling the drive axle assembly Remove the parts in the order listed 1 Middle drive gear 1 2 Bearing 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 washer 1 7 5th wheel gear 1 8 Circlip 2 9 To...

Страница 422: ...Q ty Remarks A Toothed spacer 1 B Toothed lock washer 1 C Toothed lock washer retainer 1 D 4th wheel gear 1 E Washer 1 F 1st wheel gear 1 G Bearing 1 H Washer 1 I Drive axle 1 For assembly reverse th...

Страница 423: ...clutch side NOTE Remove the main axle assembly with the slide hammer bolt 1 and weight Slide hammer bolt YU 01083 1 Weight J 6125 7 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies t...

Страница 424: ...rk guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum assembly shift drum segment 1 Damage wear Replace the shift drum...

Страница 425: ...ation pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective...

Страница 426: ...sponding hole in the upper crankcase The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Make sure the drive axle bearing circ...

Страница 427: ...cer Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Balancer lever 1 Refer to INSTALLING THE FRONT BALANCER 2 Balancer shaft 1 3 Washer 2 4 Bearing 2 5 Balancer gear 1 6 A...

Страница 428: ...es Refer to FUEL INJECTION SYSTEM in chapter 7 Clutch cover Refer to CLUTCH 1 Balancer cover 1 2 Balancer cover gasket 1 3 Balancer lever 1 Refer to INSTALLING THE REAR BAL ANCER 4 Balancer shaft 1 5...

Страница 429: ...n bearings 2 Damage wear Replace absorbers Damage wear Replace INSTALLING THE FRONT BALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the b...

Страница 430: ...stalling the balancer shaft 4 Install balancer lever 1 balancer lever bolt 2 NOTE Temporarily tighten the balancer lever bolt LT 5 Tighten balancer shaft 1 NOTE Tighten the balancer shaft to the speci...

Страница 431: ...ALANCER 1 Install balancer weight 1 absorbers balancer gear 2 bearings washers NOTE Align the punch mark a in the balancer weight with the mark b in the balancer gear 2 Align T mark on the pickup coil...

Страница 432: ...ven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the primary driven gear point d Make sure that the slot e is facing in the direction indicated in the illus...

Страница 433: ...olt 1 balancer shaft pinch bolt 2 NOTE Make sure that the balancer shaft does not rotate T R 14 Nm 1 4 m kg 10 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 7 Start the engine and check that there is no abnormal...

Страница 434: ...r to SEATS AND FUEL TANK in chapter 3 Side cowlings front cowling assembly Refer to COWLINGS AND COVERS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator cap 1 2 Coolant...

Страница 435: ...1 Conduit hose 1 12 Radiator inlet hose 1 Disconnect 13 Plunger control unit hose 2 1 Disconnect 14 Oil cooler outlet hose 1 Disconnect 15 Horn connector 4 Disconnect 16 Radiator fan motor coupler 1 D...

Страница 436: ...sure Below the specified pressure Replace the radiator cap a Install the radiator pressure tester 1 and radiator pressure tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten...

Страница 437: ...he specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below...

Страница 438: ...d Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Radiator assembly Refer to RADIATOR 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jac...

Страница 439: ...faces of the oil cooler and the crankcase with a cloth dampened with lacquer thin ner 2 Install O ring oil cooler NOTE Make sure the O ring is positioned properly 3 Fill cooling system with the specif...

Страница 440: ...COOL OIL COOLER 4 Check cooling system Leaks Repair or replace any faulty part 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIA...

Страница 441: ...chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Air cut off valve assembly hoses Refer to AIR INDUCTION SYSTEM in chapter 7 1 Plunger control unit hose 1 1 Disconnect 2 Thermostat a...

Страница 442: ...ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed 1 Thermostat housing cover 1 Refer to ASSEMBLING THE THERMO STAT ASSEMBLY 2 Thermostat 1 3 Thermostat housing 1 F...

Страница 443: ...e water observe the ther mostat and thermometer s indicated tem perature 1 Thermostat 2 Thermometer 3 Water 4 Container Fully closed Fully open NOTE If the accuracy of the thermostat is in doubt repla...

Страница 444: ...ERMOSTAT ASSEMBLY 1 Lubricate O ring thermostat assembly and thermo stat assembly inlet pipe 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT i...

Страница 445: ...der listed NOTE It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Right side cowling Refer to COWLINGS AND COVERS in chapter 3 E...

Страница 446: ...Part Q ty Remarks 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump 1 Refer to INSTALLING THE WATER PUMP For installation...

Страница 447: ...the parts in the order listed 1 Water pump housing cover 1 Refer to ASSEMBLING THE WATER PUMP 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8...

Страница 448: ...from the inside of the water pump housing 2 3 Remove oil seal 1 bearing 2 NOTE Tap out the bearing and oil seal from the out side of the water pump housing EAS00473 CHECKING THE WATER PUMP 1 Check wa...

Страница 449: ...CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools Before installing the water pump seal apply Quick Gasket 2 to the water...

Страница 450: ...Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in 5 Install impeller 1 circlip NOTE After installation check that the impeller shaft rotates smoothly New 6 Install O ring NOTE Lubricat...

Страница 451: ...New T R 12 Nm 1 2 m kg 8 7 ft lb 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 crankcase with the specified amount of the recom...

Страница 452: ...hose 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A O2 sensor B Catalytic converter C Crankshaft position sensor D Coolant temperature sensor E Spark plug F Cylinder identi...

Страница 453: ...Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L...

Страница 454: ...fuel injection stop function is active the warning light blinks while the start switch is being pressed to start the engine If a malfunction in the system is detected by the self diagnostic function...

Страница 455: ...ight illuminates 1 4 seconds each time the main switch is turned ON The ECU performs a self diagnosis during this time and turns OFF the light thereafter 2 Warning control when unable to start engine...

Страница 456: ...y observing the self diagnostic fault code number that appears on the multi function meter and cross referencing it on the fault code number table When used in conjunction with the troubleshooting det...

Страница 457: ...el ratio feed back compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Able Able 14 Faulty intake air pressure sensor pipe system a hose is detached causing...

Страница 458: ...isted up to that point Able Able 12 Crankshaft position sen sor Stops the engine by stopping the injection and ignition Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system...

Страница 459: ...lect the applicable sensor or actuator from the diagnostic code table If a diagnostic code is available proceed with the operation procedure given below in order to verify the operating conditions of...

Страница 460: ...g the operation of the displayed diagnostic code Verifying various sensors The data representing the operating con ditions of the sensors appears on the trip LCD throttle position sensor angle cool an...

Страница 461: ...einstating the ECU Verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera tion that is applicable to the malfunctioning item Refer to...

Страница 462: ...e air pressure sensor Malfunction in ECU 03 Or a stuck throttle position sensor is detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective sensor stuck thro...

Страница 463: ...in ECU Malfunction in other areas of the fuel system 33 Open circuit is detected in the primary wire of the ignition coil 1 4 Open or short circuit in wiring harness Malfunction in ignition coil Malfu...

Страница 464: ...n of the vehicle pulses that are gen erated when the tire is spun 0 999 resets to 0 after 999 OK if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off switch...

Страница 465: ...or 4 Take the same actions as No 36 on injector 4 If the engine stop switch is ON turn it OFF once and then turn it back ON Same as above 48 AI system solenoid After 1 second has elapsed from the time...

Страница 466: ...shooting through the self diagnostic function Refer to Troubleshooting details Light does not turn ON NG Inspect and repair the wiring harness OK Only the engine trouble warning light does not turn O...

Страница 467: ...ing condition of the coupler If there is a malfunction repair it and connect it securely Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Code No 12 Symp...

Страница 468: ...instated by turn ing the main switch ON Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White...

Страница 469: ...te Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue Defective intake air pressure sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 3 Open or short circui...

Страница 470: ...0 V Power supply wire open circuit 0 V Check for open circuit and replace the throttle position sensor Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or shor...

Страница 471: ...Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black...

Страница 472: ...e main switch ON Defective coolant temperature sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Open or short circuit in wiring harness or sub lead Repair or replace if there is...

Страница 473: ...ure sensor coupler Main wiring harness ECU coupler Code No 24 Symptom No normal signal is received from the O2 sensor Used diagnostic code No Inspection operation item and probable cause Operation ite...

Страница 474: ...f defective Reinstated by starting the engine warming it up until the coolant tem perature is 60 C 140 F or more and then running it between 2 000 3 000 r min until the engine trouble indicator turns...

Страница 475: ...or short circuit Main wiring harness Black Blue White Gray Green Blue The fuel pressure is too high Compare the fuel pressure at idle and with throttle open About the same Normal Too high Inspect the...

Страница 476: ...nd secondary coils for continuity Replace if defective Refer to IGNITION SYSTEM in chapter 8 Reinstated by starting the engine and operating it at idle Open or short circuit in lead wire Repair or rep...

Страница 477: ...Replace if defective Refer to TRANSMISSION in chapter 5 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Main wiring harness Sky blue Sky blue 2 Connected s...

Страница 478: ...nction is detected in the ECU the fault code number might not appear on the meter Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement m...

Страница 479: ...gnosis mode Using the results of the diagnosis mode inspection as reference estimate the cause of the mal function and carry out the inspection and repair of the affected area Symptom The engine troub...

Страница 480: ...e headlight relay 1 Check the operation of the headlight Classify the malfunctions Malfunction related to the relay Malfunction related to the wiring harness Malfunction in the headlight itself Relay...

Страница 481: ...fan does not operate Inspect the fan Refer to COOLING SYSTEM in chapter 8 Defective replace Check the continuity at the contact point of the radiator fan motor relay Refer to COOLING SYSTEM in chapte...

Страница 482: ...od 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode and in case the area of the malfunction has been narrowed down in the...

Страница 483: ...em relay Open circuit in wiring harness Disconnected battery Defective crankshaft position sensor Defective sidestand switch Tripped lean angle cut off switch Open circuit in ignition coil primary lin...

Страница 484: ...ber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 O2 sensor coupler 1 Disconnect 2 Cy...

Страница 485: ...5 5 11 11 3 8 8 7 11 11 6 Order Job Part Q ty Remarks 8 Throttle cable 2 Disconnect 9 Plunger control unit hose 1 1 Disconnect 10 Plunger control unit hose 2 1 Disconnect 11 Throttle body joint 4 For...

Страница 486: ...sconnect 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor 1 Disconnect 4 Cylinder 1 injector coupler 1 Disconnect 5 Cylinder 2 injector coupler 1 Disconnect 6 Cylinder 3 in...

Страница 487: ...ION SYSTEM 10 12 4 5 6 7 2 8 3 9 11 13 14 15 1 Order Job Part Q ty Remarks 12 Intake air pressure sensor 1 13 Fuel distributor 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse th...

Страница 488: ...DY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor clean...

Страница 489: ...lator at the joint c Connect the mity vac set 2 onto the nega tive pressure hose from the pressure regu lator d Connect the pressure gauge 3 and adapter 4 onto the fuel injector pipe e Install the fue...

Страница 490: ...vacuum pressure as described below NOTE The vacuum pressure should not exceed 100 kPa 1 mm Hg 0 039 in Hg Faulty Replace the pressure regulator Increase the vacuum pressure Fuel pressure is decreased...

Страница 491: ...ed exhaust gases is approximately 600 1 112 F to 700 C 1 292 F EAS00508 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions...

Страница 492: ...7 41 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut off valve 2 Reed valve 3 Air filter case To cylinder 4 To cylinder 3 To cylinder 2 To cylinder 1 1 2 4 3...

Страница 493: ...ng the air cut off valve assembly and hoses Remove the parts in the order listed Rider seat fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 1 Air cut off valve assembly 1 2 Hose...

Страница 494: ...s Remove the parts in the order listed Air cut off valve assembly hoses Thermostat assembly Refer to THERMOSTAT in chapter 6 Spark plug caps 1 Reed valve cover 1 1 2 Reed valve cover 2 3 1 3 Reed valv...

Страница 495: ...CTION SYSTEM 1 Check hoses Loose connection Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed fibre reed stopper reed valve seat Cracks damage Replace the reed valv...

Страница 496: ...ts fuel tank T bar rubber sheet Refer to SEATS AND FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 1 Clamp 2 2 Canister charge hose 1 Disconnect 3 Rollover valve 1 4 Canis...

Страница 497: ...ield drive unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake switch 6 Clutch switch 7 Fuse box 8 Radiator fan motor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil lev...

Страница 498: ...e sensor 4 Atmospheric pressure sensor 5 Lean angle cut off switch 6 ECU 7 Starting circuit cut off relay 8 Speed sensor 9 Cylinder identification sensor 0 O2 sensor A Crankshaft position sensor B Hea...

Страница 499: ...When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration simila...

Страница 500: ...TINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch R W L W B R B R W B W B R B R W Y Br L W BLACK L Y B Y B Y L Y BLACK BLACK B...

Страница 501: ...4 Dimmer switch 5 Horn switch 6 Windshield position switch 7 Turn signal switch 8 Front brake light switch 9 Engine stop switch 0 Start switch A Rear brake light switch B Neutral switch C Sidestand s...

Страница 502: ...B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning...

Страница 503: ...f the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity wit...

Страница 504: ...ter No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect...

Страница 505: ...W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B...

Страница 506: ...spark Dynamic spark tester YM 34487 Pocket tester YU 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignitio...

Страница 507: ...ignition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark plug lead Connect the pocket tester 1k to the...

Страница 508: ...n Tester positive probe gray 1 Tester negative probe black 2 Measure the crankshaft position sensor resistance Crankshaft position sensor resis tance 420 8 569 3 at 20 C 68 F between gray and black Is...

Страница 509: ...cut off relay for continuity Tester positive probe blue green 1 Tester negative probe blue yellow 2 Continu ity Tester positive probe blue yellow 1 Tester negative probe blue green 2 No conti nuity Lg...

Страница 510: ...D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W...

Страница 511: ...the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one o...

Страница 512: ...03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the con...

Страница 513: ...y from the wire harness Connect the pocket tester 1 to the starting circuit cut off relay terminals as shown Measure the starting circuit cut off relay for continuity as follows Lg L G L Y Sb B Y B R...

Страница 514: ...Tester positive probe red 3 Tester negative probe black 4 Does the starter relay have continuity between red and black Replace the starter relay R B R L W R W 7 Main switch Check the main switch for c...

Страница 515: ...K Replace the clutch switch 12 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch 13 Wiring Check the entire st...

Страница 516: ...der Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Throttle bodies Refer to FUEL INJECTION SYSTEM in chapter 7 1 Starter motor lead 1 Disconnect 2 Starter motor...

Страница 517: ...ft Ib Order Job Part Q ty Remarks Disassembly the starter motor Remove the parts in the order listed 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat 1 5 Washer 1 6 Lock washer 1 7 Oil...

Страница 518: ...w New New 1 2 6 5 4 3 3 7 8 C A B A 0 9 T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks A O ring 1 B Starter motor yoke 1 C Armature assembly 1 For assembly reverse the disassembly procedure S...

Страница 519: ...pecification Replace the starter motor Commutator wear limit 23 5 mm 0 93 in 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been...

Страница 520: ...YU 03112 Armature coil Commutator resistance 1 0 024 0 030 at 20 C 68 F Insulation resistance 2 Above 1 M at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush...

Страница 521: ...he brush seat with the tab b in the starter motor front cover 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 yo...

Страница 522: ...Sb B Y L W B R B Lg R B L G L Y B Y L Y z Br L Br L L Br G Br L R W R W R W Br L R W L W R B Br L Br Br B Br B Br B B R B R B C R R B L Y L Y B R L R L R B R L Y R L A A Br G Br G A Br W Br W A G B G...

Страница 523: ...or continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum...

Страница 524: ...ter positive probe white 1 Tester negative probe white 2 Tester positive probe white 1 Tester negative probe white 3 Measure the stator coil resistances Stator coil resistance 0 15 0 23 at 20 C 68 F I...

Страница 525: ...L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E...

Страница 526: ...ight high beam indicator light taillight or meter light Pocket tester YU 03112 1 Main tail position light and headlight fuses Check the main tail position light and head light fuses for continuity Ref...

Страница 527: ...e headlight relay 1 for continuity Battery positive terminal blue black 1 Battery negative terminal yellow black 2 Tester positive probe red yellow 3 Tester negative probe green blue 4 Does the headli...

Страница 528: ...s the lighting system s wiring properly con nected and without defects Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair t...

Страница 529: ...st be repaired R W G W Y L Lg Y Ch Dg L R G B W Br R W 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Are the meter light bulb and socket OK Replace the meter light...

Страница 530: ...age Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Tester positive probe blue 1 Tester negative probe black 2 Set the main switch to ON Measure the voltag...

Страница 531: ...8 35 ELEC LIGHTING SYSTEM...

Страница 532: ...Y L Y R L B L Y G Y B k c Ch B Y G B B G P G B Y G B Y L R G W R L O B O B O B B L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B...

Страница 533: ...ing light _ Left turn signal indicator light a Right turn signal indicator light c Oil level switch h Turn signal switch i Horn switch j Horn k Front turn signal light left l Front turn signal light r...

Страница 534: ...lighting windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system hazard lighting windshield motor and backup fuses OK Replace the fuse s...

Страница 535: ...the horn terminal as shown Tester positive probe brown 1 Tester negative probe ground Set the main switch to ON Measure the voltage 12 V of black white at the horn terminal Is the voltage within spec...

Страница 536: ...the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail light assembly coupler wire harness side as shown Tester positive probe yellow 1 Teste...

Страница 537: ...Is the turn signal switch OK Replace the left han dlebar switch 3 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Tester positive probe brown green 1 Tester negati...

Страница 538: ...signal light Tester positive probe dark green 2 Tester negative probe ground Ch Dg Ch Dg Ch B Y L Dg Y L B 1 2 R W G W Y L Lg Y Ch Dg L R G B W Br R W Set the main switch to ON Set the turn signal sw...

Страница 539: ...onti nuity NOTE When you switch the positive and negative tester probes the readings in the above chart will be reversed Are the tester readings correct Replace the starting circuit cut off relay Lg L...

Страница 540: ...pan Check the engine oil level switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine oil level switch OK Replace the engine oil level switch 3 Voltage Connect the pocket tester DC 20 V t...

Страница 541: ...e stopper Fuel sender resistance Full position of the float 19 21 at 20 C 68 F Empty position of the float 139 141 at 20 C 68 F Is the fuel sender OK Replace the fuel pump G W B B R L 2 Voltage Connec...

Страница 542: ...L BLACK BLACK D G W R L l Dg B L B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y...

Страница 543: ...e coolant temperature gauge needle fails to move when the engine is warm Pocket tester YU 03112 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for co...

Страница 544: ...ect the green white 1 and black blue 2 terminals with a jumper lead 3 shown Does the radiator fan motor turn The radiator fan motor is faulty and must be replaced G W B L 6 Radiator fan motor relay Di...

Страница 545: ...t step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating pha...

Страница 546: ...iring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly con nected and without defects Replace the ECU Properly connect or repair the cooling sy...

Страница 547: ...Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y Gy W L O B Y B G Y Y L R B G B L B L O R W O L R L R L D B L B L E W L B L Gy G B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L...

Страница 548: ...EAS00749 YES NO EAS00750 YES NO If the fuel injection system fails to oper ate Pocket tester YU 03112 1 Main fuel injection system and ignition fuses Check the main fuel injection system and ignition...

Страница 549: ...k Replace the fuel injection system relay R R L R B L Y 6 Fuel pump resistance Disconnect the fuel pump coupler from the fuel pump Connect the pocket tester 1 to the fuel pump coupler as shown Tester...

Страница 550: ...ification sensor output voltage Cylinder identification sensor output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less Is the cylinder identification sensor OK Replace th...

Страница 551: ...Test step Coolanttemperature Continu ity Coolanttemperature sensor 1 Less than 105 C 221 F NO 2 More than 105 C 221 F YES 3 More than 100 C 212 F YES 4 Less than 100 C 212 F NO Test steps 1 2 Heating...

Страница 552: ...bject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it T R Intake air temperature sensor 18 Nm 1 8 m kg 13 ft lb Is the intake air temperat...

Страница 553: ...atmo spheric pressure sensor L B L P 14 AI system solenoid Remove the AI system solenoid coupler from the wire harness Connect the pocket tester 1 to the AI system solenoid terminal as shown Tester p...

Страница 554: ...oline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check...

Страница 555: ...osition sensor d Connect the pocket tester 1k to the throttle position sensor e While slowly opening the throttle check that the throttle position sensor resistance is within the specified range NOTE...

Страница 556: ...e throttle position sensor b Remove the throttle position sensor from the throttle body c Connect the pocket tester 1k to the throttle position sensor d Measure the maximum throttle position sen sor r...

Страница 557: ...ightly from those specified Tester positive probe yellow terminal 3 Tester negative probe black blue terminal 2 Throttle position sensor resis tance 0 5 1 0 k at 20 C 68 F yellow black blue 3 Adjust t...

Страница 558: ...lds Loosen the throttle posi tion sensor screws 4 Connect the pocket tester 100 to the throttle position sensor e Adjust the throttle position sensor angle so the measured resistance is within the spe...

Страница 559: ...B Dg Dg C W W W W Y Ch Dg Lg L A Lg Lg C A C R G R G A G W G W B Ch Ch Br W B L R LO B G W B L x i f g h Br j j X Y Z a b UP DOWN ON OFF Dg Br W Ch B L L D L L E Y Y B C E E D S R W Br R E B W B3 P Y...

Страница 560: ...the main windshield motor and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main windshield motor and backup fuses OK Replace the fuse s 2 Battery Check the condition o...

Страница 561: ...ink until the windshield has stopped and is all the way down If the neutral indicator light does not turn off replace the windshield drive unit 5 Wiring Check the entire windshield drive system s wiri...

Страница 562: ...r damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly...

Страница 563: ...Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incor...

Страница 564: ...FT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmiss...

Страница 565: ...ed clutch release cylinder Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00855 OVERHEATING ENGINE Clogged coolant passages Heavy carbon buildu...

Страница 566: ...EAS00860 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...

Страница 567: ...EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts...

Страница 568: ...INKS QUICKLY Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb HORN DOES NOT SOUND Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Fa...

Страница 569: ...l level warning light Z Neutral indicator light Multi function meter Engine trouble warning light High beam indicator light _ Left turn signal indicator light a Right turn signal indicator light b Met...

Страница 570: ......

Страница 571: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A...

Страница 572: ...e White Yellow White Black Yellow Black Yellow Green Yellow Blue Yellow Red D D D R LR B D ON OFF 1 RED RED BLACK BLACK BLACK BLACK BLACK GRAY 9 F 0 7 8 6 A A A A B C B B A A A A A A B B B B y BLACK B...

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